C26PRO SERIES SERVICE MANUAL PRO-M

Transcription

1 C26PRO SERIES SERVICE MANUAL PRO-M MA

2

3 Index of INTRODUCTION 1 Introduction How to use the assistance manual Radio remote control identification General diagnostic of the radio remote control Glossary MAPRME01 - Rev.0 1-1

4 1-2 MAPRME01 - Rev.0

5 1 Introduction This technical assistance manual contains all information regarding the radio remote control replacement, programming and diagnostic procedures. For this reason it is COMPLEMENTARY TO and does not replace the user manual, where warnings and indications regarding radio remote control installation, usage and maintenance can be found. To operate correctly and safely, those who use this manual must: - become familiar with and respect all the warnings and indications given in the user manual - use the radio remote control technical data sheet (a copy of this sheet can be found inside the receiving unit and another copy can be found in the documentation included with the user manual). The information contained in this manual is subject to modification without notice and is not binding. No parts of this manual may be reproduced by any means without the written permission of Autec (including recording and photocopying). MAPRME01 - Rev.0 1-3

6 1.1 How to use the assistance manual 1.1 How to use the assistance manual Using the manual Follow the indications given below according to the situation: THE RADIO REMOTE CONTROL DOES NOT WORK: FINDING AND CORRECTING THE FAULT If the "machine + radio remote control" system does not work correctly, begin from the diagnostic paragraph (see General diagnostic of the radio remote control on page 1-6) which sends you to the diagnostic sections in the other parts of the manual. Follow the indications given in the flow chart step by step. SPARE PARTS: SEARCHING FOR INDIVIDUAL CODES If spare parts have to be ordered, refer to section 2 "Exploded view and spare parts" of each chapter, which contains a list showing all the part codes of the unit described in that chapter. SPARE PARTS: REPLACEMENT If parts of the radio remote control have to be replaced, use the list given in the "Replacement index". This list can be found at the beginning of the relative unit chapter. RADIO REMOTE CONTROL FUNCTIONS: MODIFYING THE PROGRAMMING If the radio remote control function programs are to be modified, use the list given in the "Glossary" ( 1.4). Once the relative function has been found, follow step by step the cross-references to the different chapters of the manual. Structure of the manual This manual is structured as follows: - CHAPTER 1 An introduction to and explanation of the manual - CHAPTER 2 Batteries and battery charger - CHAPTER 3 Transmitting unit - CHAPTER 4 and 5* Receiving unit * chapter 5 may not be included 1-4 MAPRME01 - Rev.0

7 1.2 Radio remote control identification 1.2 Radio remote control identification Model + = MA (REMOTE SET-UP) + = PRO-M Plate Identification of the serial number (to unequivocally identify the radio remote control) Identification of the year of production (to verify the guarantee validity) Identification of the "Type" and "Model" (to identify the radio remote control from a homologation point of view) Identification of the technical data (to identify some of the characteristics of the radio remote control: the most useful characteristic is the frequency) Identification of the technical data (conformity with the 99/05 R&TTE Directive) Identification of brands and certification MAPRME01 - Rev.0 1-5

8 1.3 General diagnostic of the radio remote control 1.3 General diagnostic of the radio remote control If the "radio remote control + machine" system does not operate correctly, first check if the problem has to do with the radio remote control or the machine. Before carrying out any verification, therefore, connect the wired control station. If the machine does not start, the problem has to do with the machine itself. Alternatively, if the machine starts normally and operates correctly but only when activated from the wired control station the problem involves the radio remote control. In this case, after having carried out the power on and starting procedure, follow the indications given below. 1. If the machine works intermittently because the radio remote control continually switches off, change the radio frequency being used (with the transmitting unit powered and started, keep the START pushbutton pressed for 5-6 seconds. A prolonged beep accompanied by the powering of both the signalling LEDs indicates that the frequency has changed. During this operation the receiving unit switches off. To start operating again press the START pushbutton, as for the normal starting procedure). 2. If the machine works partially, i.e. some commands are not activated while others are, replace: - the actuators of the faulty commands in the transmitting unit and - if necessary, the corresponding relay cards in the receiving unit. This information can be found in the technical data sheet of the radio remote control. 3. If the machine does not start at all, follow the flow chart given below. Is the green LED on the transmitting unit flashing slowly? Refer to the battery and battery charger diagnostic ( 2.1) Is the POWER light on the receiving unit lit? Is the power supply plug connected? Correctly connect the plug. Does the system start? Are the power supply value and the wiring correct? Correctly supply the receiving unit. Does the system start? Refer to the diagnostic of the relative receiving unit. ( 4.1) or ( 5.1) 1-6 MAPRME01 - Rev.0

9 1.4 Glossary 1.4 Glossary Actuator Address Address keys Analogue receiving module Antenna Automatic scan Automatic switching off Battery Command An actuator is a device present in the transmitting unit. The operator uses actuators to activate fixed commands which are sent to, received by and also actuated by the receiving unit. The joysticks, selectors and pushbuttons are all actuators. The address is a number (value) used by the receiving unit to differentiate the telegrams sent to the respective transmitting unit. The address is contained in the address keys and renders the radio remote control unique. (see Address key on page 3-25) or (see Address key on page 4-30) or (see Address keys on page 5-42) There are two address keys: a yellow one which should be inserted into the transmitter encoder module, and a grey one which should be inserted into the receiver decoder module. These keys are necessary for correct radio remote control operation because they contain the unequivocal address of the system. The analogue receiving module is a module that is present in the receiving unit and is necessary not only for activating commands but also the intensity at which to activate them. The outputs of these commands can be controlled either by voltage or by current (PWM). The antenna is the device that permits the transmission and reception of the telegram that contains the commands activated in the machine by the receiving unit. The antenna can be internal, integrated or external. Automatic scan is an operation mode of the radio remote control that makes it possible to work at any one of the frequencies available inside the permitted band. When set in this mode the receiving unit continues to scan all the frequencies until it recognises a telegram that it can decode. From then on, the operating frequency does not change. A radio remote control is normally pre-set by Autec in this mode, which makes it possible to move the operating frequency in case of interference (see "Frequency change") without having to intervene inside the transmitting unit or the receiving unit. (see Automatic scan mode on page 3-9) or (see Automatic scan mode on page 4-11) or (see Automatic scan mode on page 5-11) Automatic switching off (or power off) occurs when the transmitting unit switches off automatically by itself. This happens when the battery is not sufficiently charged and/or the radio remote control is not used for approximately 3 and a half minutes. This function can be deactivated. (see Connectors on page 3-15) The battery supplies power to the transmitting unit and guarantees operation for at least one working day (8 hours). The battery charge state is indicated by two LEDs present on the transmitting unit. When the battery is flat, it should be recharged using the supplied battery charger. Only Autec batteries can be used. Activating a command means activating an actuator of the transmitting unit. The actuation of a movement or a selection in the machine commanded by the receiving unit corresponds to this action. MAPRME01 - Rev.0 1-7

10 1.4 Glossary Command common Dip switch ENABLE FLOW Function Horn Interference Joystick Joystick axis Manual selection Movement command Operating frequency change The command common is the wiring cable of the receiving unit that supplies the relay contacts relative to the command. All the commons must be in series with the STOP contact. The dip switch is a device used for programming some functions. It can assume two statuses (ON and OFF), which correspond to the activation and deactivation of a specific operation. (see Dip switches on page 3-7) or (see Dip switches on page 4-8) or (see Dip switches on page 4-24) or (see Dip switches on page 5-8) or (see Welding points and dip switches on page 5-33) or (see Welding points and dip switches on page 5-39) ENABLE is a signal present in the receiving unit when the unit is in radio link with the transmitting unit. Only if this signal is present (and therefore the relative relay is active) can the commands that are sent be actuated. If programmed, FLOW activates a movement command. This function commands the solenoid valve which pressurises the oil in the primary hydraulic circuit of the distributor. (see Welding points on page 4-25) A function is a well-defined task carried out by the radio remote control. A function can be activated or deactivated. The machine horn/alarm (when connected) can be activated by pressing the START pushbutton with the transmitting unit started. Radio interference is a disturbance in the radio link between the transmitting unit and the receiving unit. It can be caused by any radio equipment (radio remote controls included) operating in the same area. In case of interference the passive emergency intervenes automatically to guarantee safety. A joystick is an actuator present on the transmitting unit. To activate this actuator, move it from its rest position. An axis is a spatial direction along which a joystick can be moved. Normally, a joystick can have one single axis or two right-angled axes. Each axis corresponds to a fixed movement command. Manual selection is an operating mode of the radio remote control that makes it possible to work at a single fixed frequency inside the permitted band. To set this mode it is necessary to set the dip switches in the radio transmitting and receiving module. (see Manual frequency mode on page 3-11) or (see Manual frequency mode on page 3-11) or (see Manual frequency mode on page 5-13) A movement command is a command that causes the machine or part of it to move physically. As regards the receiving unit, the common of the movement commands must be obtained from the series of the STOP contact and the SAFETY contact. Given that the SAFETY contact only closes when a movement command is transmitted, the radio remote control is protected from involuntary movements when the actuators are in the rest position. When the automatic scan mode is set in a radio remote control, changing the operating frequency makes it possible to move the operating frequency without having to intervene inside either the transmitting unit or the receiving 1-8 MAPRME01 - Rev.0

11 1.4 Glossary Operating range Passive emergency Operating frequency Power on Power supply Programming Pushbutton PWM Radio link Radio receiving module unit. The frequency can only be changed if the radio remote control is operating in the automatic scan mode, and is very useful in cases of interference. The operating frequency change procedure is as follows: - power and start the transmitting unit - keep the START pushbutton pressed for 5-6 seconds (an extended beep accompanied by the powering of both the LEDs present on the transmitting unit indicate that the frequency has changed) - start the transmitting unit again. The typical operating range of a radio remote control is the distance within which a transmitting unit can create a stable radio link with the receiving unit and therefore command the machine. The passive emergency is a function of the radio remote control that intervenes following an irregular situation that occurs during operation. When radio remote control linkage is disturbed, incorrect or interrupted, the receiving unit independently decides to stop the radio remote control. This function can be set at 0.5 or 1.5 seconds. (see Welding points on page 4-25) or (see Welding points and dip switches on page 5-33) or (see Welding points and dip switches on page 5-39) The operating frequency is the frequency of the radio link between the transmitting unit and the receiving unit. This frequency can be fixed (see "Manual selection") or variable (see "Automatic scan"). Power on consists of supplying voltage to the units that make up the radio remote control. In the transmitting unit this operation consists of inserting the starting key and turning it to position "l". The power supply is the supply that allows the radio remote control to operate. The power supply of the transmitting unit is supplied by the internal battery while the power supply of the receiving unit is external (in DC or AC). Programming means selecting whether to activate a radio remote control function or not, setting values or in any case modifying radio remote control operation within a set of permitted values. A pushbutton is an actuator present in the transmitting unit. It activates when pressed and deactivates when released. PWM (Pulse Width Modulation) is the modulation that regulates the output current of the analogue receiving module and therefore of the receiving unit. This current commands the solenoid valves of the radio remote controlled machine. The radio link of a radio remote control is the radio-frequency transmission that is created between the transmitting unit and the receiving unit. This link occurs at the operating frequency at which the telegram is modulated. The radio receiving module is a module present in the receiving unit which transforms the radio signal into a low frequency signal that is decoded by the radio transmitter encoder module. The radio receiving module can search for the radio signal that is sent by the transmitting unit at a set frequency (see "Manual selection") or at a variable frequency (see "Automatic scan"). MAPRME01 - Rev.0 1-9

12 1.4 Glossary Radio remote control Radio transmitter encoder module Receiver decoder module Receiving unit REMOTE SET-UP Reply time RPM Rest position SAFETY Selection command Selector A radio remote control is the radio equipment which is used to command machines from a distance. It is made up of a portable transmitting unit, from which the user can command the machine from a distance, and a receiving unit installed on-board the machine itself. The radio transmitter decoder module is the module in the transmitting unit that: - creates the telegram to be sent by coding the activated commands by way of an address. - transforms this low frequency signal into a high frequency radio signal, the value of which can be set (see "Manual selection") or variable (see "Automatic scan"). The receiver decoder module is a module present in the receiving unit that decodes the telegram, transforming it into commands to be carried out by the machine. The receiver decoder module contains the address key that permits recognition of the unequivocal address of the radio remote control. The receiving unit is a radio apparatus installed on-board the radio remote controlled machine which receives the commands sent by the transmitting unit and makes the machine carry them out. The REMOTE SET-UP function makes it possible to set the proportional outputs from a distance using a selector that is present on the transmitting unit. (see Preparation for setting on page 4-19) or (see Preparation for setting on page 5-19) The reply time is the time that passes from activation of the command that is to be actuated until true actuation of this command by the radio remote controlled machine. The STOP command reply time must never exceed 550 ms. The RPM function is necessary for increasing or decreasing the motor turns of the machine. A precise selector, which is also used to set the outputs (see "REMOTE SET UP"), exists for this operation. The rest position, also called neutral or zero, of an actuator is the position at which the actuator is not active, therefore the transmitting unit does not send commands to the receiving unit. This position is constantly controlled by the SAFETY function to protect the system from involuntary movements in case of failure. The SAFETY is a safety function that protects the system from involuntary movements caused by possible failures. This function constantly controls the rest position of the movement actuators of the transmitting unit and is available at the SAFETY relay of the receiving unit. (see Welding points on page 4-17) or (see Welding points and dip switches on page 5-33) or (see Welding points and dip switches on page 5-39) A selection command is a command that does not cause a physical movement of the machine or part of it. In the receiving unit, the common of the selection commands may not be in series with the SAFETY contact, while it must be in series with the STOP contact (excluding the TIMED STOP). A selector is a type of actuator present in the transmitting unit that can be either a lever or round MAPRME01 - Rev.0

13 1.4 Glossary Serial number Setting Setting Signal Start Starting STOP Switching off (power off) Telegram Technical data sheet Transmitting unit Trimmer Among those present on the transmitting unit, there is a speed selector that is necessary for making the machine work at different speeds, according to operative needs. The serial number is a group of figures that unequivocally identify the radio remote control. This number is given on the identification plate present on the transmitting unit and the receiving unit. (see Radio remote control identification on page 1-5) Setting is an operation that activates or deactivates a radio remote control function. This function is normally carried out when a dip switch or welding point are to be modified. Setting is an operation that consists of fixing set values of radio remote control operation. It is normally carried out following a precise procedure. A signal is an electric impulse or an electromagnetic radiation that corresponds to an elementary piece of information. Each command that is sent is transformed into a signal. Start means starting and powering the radio remote control. Starting consists of activating the START pushbutton on the transmitting unit until the green LED starts flashing. This operation finishes when the ENABLE light present on the receiving unit illuminates.. From that moment onwards until subsequent switching off, the commands sent by the transmitting unit are received and actuated by the receiving unit. The STOP command should be used each time it is necessary to immediately stop the machine in order to verify any dangerous condition. It can be actuated by pressing the relative mushroom pushbutton. To start working when this command has been activated, rotate the STOP pushbutton in the indicated direction and repeat the power on and starting procedure. Switching off consists of disconnecting the power from the transmitting unit, interrupting in this manner the radio link. To do this insert the starting key and turn it to "O". Switching off can also be automatic (see "Automatic switching off"). A telegram is a set of bits that the transmitting unit sends to the receiving unit. It is modulated at a determinate frequency and contains, as a minimum, the unequivocal address of the radio remote control and the commands that the machine must carry out. A telegram is created by the transmitter encoder module and is recognised by the receiving decoder module. The technical data sheet contains the layout of the transmitting unit commands, the wiring diagram between the receiving unit and the machine, and the setting values that have been set. The installer must fill in and verify the two copies of the technical data sheet (one copy is attached to the user manual, the other is inside the receiving unit). The transmitting unit is a portable radio apparatus supplied by a battery. It sends the commands that are to be carried out by the radio remote controlled machine to the receiving unit. A trimmer is a variable resistor on some relay cards and is necessary for adjusting the values of some characteristics of the card (for example: minimum and maximum value of the outputs). MAPRME01 - Rev

14 1.4 Glossary TS (Timed STOP) Welding point Wiring TS is the command that switches off the diesel motor of the machine. It remains active for 10 seconds after the STOP pushbutton has been activated. These are points that can be present on the radio remote control electronic card and which are necessary for programming activation or deactivation of some functions. They can be programmed by closing the relative pads with a drop of solder. The wiring is the set of electric cables that connects the various parts of a radio remote control unit MAPRME01 - Rev.0

15 BATTERIES E BATTERY CHARGERS index 2 Batteries e battery chargers Battery diagnostic Spare parts MH0707L regargeable battery CH26_R battery charger MAPRME02 - Rev.0 2-1

16 2-2 MAPRME02 - Rev.0

17 2 Batteries e battery chargers In order to operate, each transmitting unit must be power supplied by a battery that supplies voltage. This battery must be exclusively of the MH0707L type. Once flat, the MH0707L batteries can only be recharged by CH26_R type battery chargers. Not using this type of battery and battery charger prejudices correct radio remote control operation. Autec cannot be held responsible for the consequences of this action. MAPRME02 - Rev.0 2-3

18 2.1 Battery diagnostic 2.1 Battery diagnostic Diagnostic Is the green LED present on the transmitting unit flashing quickly? Is the red LED present on the transmitting unit flashing slowly? The transmitting unit switches off within 15 minutes. The transmitting unit switches off within 3 minutes. The battery is flat. Insert one that is known to be charged. Is the "radio remote control + machine" system operating correctly? See battery charger diagnostic. ( 2.4) See transmitting unit diagnostic. ( 3.1) 2-4 MAPRME02 - Rev.0

19 2.2 Spare parts 2.2 Spare parts C N Code Description 2.3 F0BATT00E07A0 MH0707L battery to Nichel Metal Idrato 2.4 F0CABA01E02N0 CH260R battery charger for MH0707L (230 Vac) * 2.4 F0CABA01E03N0 CH261R battery charger for MH0707L (24 Vdc) 2.4 F0CABA01E04N0 CH262R battery charger for MH0707L (12 Vdc) 2.4 F0CABA01E05N0 CH263R battery charger for MH0707L (115 Vac) C F0CAVI00E20A0 24 Vdc and 12Vdc extendable cable for battery chargers * together with the code, indicate also the type of battery charger (given on the technical data plate) The "N " is the paragraph number that deals with the spare parts (except for the extension cable). MAPRME02 - Rev.0 2-5

20 2.3 MH0707L regargeable battery 2.3 MH0707L regargeable battery Characteristics number of NiMH elements 6 nominal voltage of 1 element (V) 1,2 total nominal voltage of the battery (V) 7,2 battery voltage after discharge (V) 8,4 voltage of the charged battery (V) 6 capacity (Ah) 1,3 number of cycles in average life 400 autonomy (hours) up to 15 recharge time (approx) 4 Recharge conditions MH0707L batteries must only be recharged using CH26_R battery chargers (see CH26_R battery charger on page 2-8). Use the battery until it is totally flat. As the battery recharges in relation to time, it should never be removed before recharging finishes (for example if the power supply to the battery charger is interrupted, the charge starts from the beginning again). Housing The battery should be inserted into its housing, which can be found in the lower part of the transmitting unit. When there is no voltage in the transmitting unit even with a charged battery, check contacts are clean and the efficiency of the battery seat. golded contacts spring 2-6 MAPRME02 - Rev.0

21 2.3 MH0707L regargeable battery Temperature intervals The battery should be recharged, used and stored within the recommended temperature limits, which are indicated in the following table. Recommended interval Permitted interval Recharge (+5 +35) C (0 +50) C Usage ( ) C ( ) C Storage (0 +45) C ( ) C As the temperature has a notable effect on battery capacity, not respecting the indicated temperature limits, voltage and duration, can permanently damage the battery elements (in this case the battery terminals have voltages of less than 6V). MAPRME02 - Rev.0 2-7

22 2.4 CH26_R battery charger 2.4 CH26_R battery charger Codes F0CABA01E02N0 CH260R battery charger supplied to 230 Vac * F0CABA01E03N0 CH261R battery charger supplied to 24 Vdc ** F0CABA01E04N0 CH262R battery charger supplied to 12 Vdc ** F0CABA01E05N0 CH263R battery charger supplied to115 Vac * * together with the code indicate also the type of battery charger (given on the technical data plate) ** the cable is extendable (F0CAVI00E20A0) and is included in the battery charger code Description ON CHARGING light END OF CHARGE light Identification plate Technical data plate CH260R and CH263R ON CHARGING light END OF CHARGE light Identification plate Extendable cable Technical data plate CH261R and CH262R Signal light The "ON CHARGING" signalling light is red and lights up when the MH0707L battery inserted in the battery charger is being recharged. The "END OF CHARGE" signalling light is green and indicates that the charge phase has ended and the battery can be used. 2-8 MAPRME02 - Rev.0

23 2.4 CH26_R battery charger Diagnostic Insert a battery into the battery charger. Does the ON CHARGING light illuminate? Insert another battery. Does the ON CHAR- GING light illuminate? The first battery is faulty The battery charger works. Return to the battery diagnostic. ( 2.1) Disconnect the power supply and open the battery charger. Is the fuse integral? Replace the fuse. Close the battery charger and supply power. The battery charger is faulty. Replace it. Does the battery charger light illuminate if another battery is inserted? Internal fuse In order to check that the battery charger is operating correctly, verify the integrity of the internal fuse. Fuse technical characteristics: F0.5A, 250 V, (5x20) mm. Recharge conditions A CH26_R battery charger can only be used with MH0707L batteries (see MH0707L regargeable battery on page 2-6). The recharge of a CH26_R battery charger lasts approx. 4 hours, after which the battery has a voltage of approx. 8.4V. As the battery recharges in relation to time, it should never be removed before the end of the recharge (for example if the power supply to the battery charger is interrupted, the charge starts from the beginning again). We recommend using the battery charger within the recommended temperature interval (+5 +35) C or at least within the permitted temperature interval (10 +50) C. MAPRME02 - Rev.0 2-9

24 2.4 CH26_R battery charger 2-10 MAPRME02 - Rev.0

25 TRANSMITTING UNIT index 3 Transmitting unit Transmitting unit diagnostic Exploded view and spare parts Radio transmitter encoder module (MTX +TC9708) Interface card (SIC97GP05A) Transmitting antenna (ANT0 ) Double axis Joystick, Penny Giles type single axis joystick, Tecnord type Double axis joystick, Gessmann type Address key STOP pushbutton Pushbutton kit, TH type Keyswitch selector Toggle switch position rotative switch Potentiometers Bottom wired control casing Bottom casing Upper casing Technical data and findings MAPRMI03 - Rev.0 3-1

26 TRANSMITTING UNIT replacements index Replacement of radio transmitter encoder module Replacement of interface card Replacement of transmitting antenna Replacement of Joystick, Penny Giles type Replacement of Joystick, Tecnord type Replacement of Joystick, Gessmann type Replacement of STOP pushbutton Replacement of pushbutton kiy, TH type Replacement of keyswitch selector Replacement of toggle switch Replacement of 11-position rotative switch Replacement of mini-potentiometer Replacement of potentiometer Opening and closing of the trasmitting unit Replacement of transmitting unit TRANSMITTING UNIT programmings index Programming of the frequency at automatic scan mode Programming of the frequency at manual frequency mode MAPRMI03 - Rev.0

27 3 Transmitting unit The model MA transmitting unit of the C26 PRO series can command machines with electric or electrohydraulic proportional drives from a distance. The distinctiveness of this unit are the proportional outputs of the machine, which can be set directly from the transmitting unit using the REMOTE SET UP function. MAPRMI03 - Rev.0 3-3

28 3.1 Transmitting unit diagnostic 3.1 Transmitting unit diagnostic Diagnostic Are the green and red LEDs lit and steady? An actuator and/ or the STOP pushbutton is/are active. Deactivate it/them. The two LEDs are not lit. Remove the battery and open the transmitting unit. If the actuator cannot be deactivated, replace it. Does the system start? Fix the internal wiring if not integral and/or correct. Does the system start? Remove the battery and open the transmitting unit. Replace the keyswitch selector ( 3.12) Does the system start? Make sure the wiring is correct. Does the system start? Replace the transmitting module ( 3.3) Does the system start? Replace the STOP pushbutton ( 3.10) Does the system start? Replace the interface card. ( 3.3) Does the system start? Replace the key address ( 3.9) Does the system start? CALL SERVICE 3-4 MAPRMI03 - Rev.0

29 3.2 Exploded view and spare parts 3.2 Exploded view and spare parts Exploded view 3.8 C C MAPRMI03 - Rev.0 3-5

30 3.2 Exploded view and spare parts Spare parts Warning N Code Description C1 A0CING00P0002 Collar strap C2 A0CING00P0003 Waist strap 3.6 A0MANI00E84A0 Double axis joystick, Penny Giles type 3.6 A0MANI00E85A0 Double axis joystick with coulisse, Penny Giles type 3.15 A0RESI04E0038 Single turn potentiometer 3.5 F0ANTE00E02A0 Transmitting antenna (frequency 433 MHz) 3.5 F0ANTE00E02B0 Transmitting antenna (frequency 472 MHz) 3.5 F0ANTE00E02C0 Transmitting antenna (frequency 458 MHz) 3.5 F0ANTE00E31A0 Transmitting antenna (frequency 870 MHz) 3.7 F0MANI00E05A0 Single axis joystick, Tecnord type 3.4 F0SCIN00E57A0 SIC97GP05A interface card 3.3 F0TXCO04E02A0 Radio transmitter encoder module (frequency 433 MHz) 3.3 F0TXCO04E02B0 Radio transmitter encoder module (frequency 472 MHz) 3.3 F0TXCO04E02D0 Radio transmitter encoder module (frequency 458 MHz) 3.3 F0TXCO04E02E0 Radio transmitter encoder module (frequency 870 MHz) 3.8 R0MANI00E03A0 Double axis joystick, Gessmann type 3.8 R0MANI00E03B0 Double axis joystick mit coulisse, Gessmann type 3.16 R0POCO12E06A0 Bottom casing -wired control casing for IR START UP 3.17 R0POCO12P06A0 Bottom casing for IR START UP 3.16 R0POCO16E03A0 Bottom wired control casing 3.16 R0POCO16E04A0 Bottom wired control casing for cable control 3.18 R0POCO16P03A0 Upper casing with 2 holes for Gessman joystick 3.18 R0POCO16P06A0 Upper casing with 3 holes for Gessman joystick 3.18 R0POCO16P07A0 Upper casing with 2 holes for Penny Giles joystick 3.18 R0POCO16P08A0 Upper casing with 3 holes for Penny Giles joystick 3.18 R0POCO16P09A0 Upper casing with 4 holes for Tecnord joystick 3.18 R0POCO16P10A0 Upper casing with 6 holes for Tecnord joystick 3.17 R0POCO16P12A0 Bottom casing 3.17 R0POCO16P13A0 Bottom casing for cable control 3.13 R0PULS00E position toggle switch (2 with return) 3.13 R0PULS00E position toggle switch 3.13 R0PULS00E position toggle switch (1 with return) 3.13 R0PULS00E position toggle switch (1 with return) 3.13 R0PULS00E position toggle switch 3.10 R0PULS00E0012 STOP pushbutton 3.11 R0PULS00E0013 Pushbutton kit, TH type 3.13 R0PULS00E position toggle switch (2 with return), 2 poles 3.13 R0PULS00E position toggle switch, 2 poles 3.13 R0PULS00E position toggle switch (1 with return), 2 poles 3.13 R0PULS00E position toggle switch, 2 poles 3.13 R0PULS00E position toggle switch (1 with return), 2 poles 3.15 R0RESI04E0041 Single turn potentiometer 3.12 R0SELE00E keyswitch selector 3.14 R0SELE00E07A0 11-position rotative switch "N " is the paragraph number which refers to the spare part. No voltage should be present when carrying out any internal operations (replacement or programming) on transmitting unit. Before proceeding, remove the battery from the transmitting unit. 3-6 MAPRMI03 - Rev.0

31 3.3 Radio transmitter encoder module (MTX +TC9708) 3.3 Radio transmitter encoder module (MTX +TC9708) Codes MTXEU03A+TC9708 Radio transmitter encoder module frequency 433 MHz MTXUK03A+TC9708 Radio transmitter encoder module frequency 458 MHz (module for UK) MTXEU06B+TC9708 Radio transmitter encoder module frequency 870 MHz MTXAU03A+TC9708 Radio transmitter encoder module frequency 472 MHz(module for Australia) Module components Always make sure that the frequencies at which the radio transmitter encoder module operates are permitted in the country where the radio remote control is to be used. Clamping holes Antenna connector Clamping holes Address connector key Dip switches Led (colour red) Interface card connector Led The red LED should only light up during starting (approx. 1 second). If it remains lit or does not light up during starting, there could be a failure in the transmitting unit. Dip switches The eight dip switches present on the radio transmitter encoder module define the operation mode of the frequency (automatic scan or manual selection) and also the operating frequency: MHz (always OFF) MHz MHz Frequency value for each MHz DIP in the ON position MHz MHz MHz ON = manual selection OFF = automatic scan The radio transmitter encoder module dip switches must always be set similarly to the dip switches of the radio receiving module. MAPRMI03 - Rev.0 3-7

32 3.3 Radio transmitter encoder module (MTX +TC9708) Replacement Disassembly Assembly 1. Open the transmitting unit. ( 3.16). Disconnect the antenna cable from the connector on the module. 8. Connect the antenna cable to the module connector. Close the transmitting unit. ( 3.16). 2. Unscrew the four screws that hold to the module to the bottom control casing. 7. Tighten the four screws that hold the module to the bottom control casing. 3. Extract the module from the bottom control casing. 6. Insert the new module into the bottom control casing. 4. Extract the address key from the module. 5. Insert the address key in the new module and control the setting of the dipswitch. 3-8 MAPRMI03 - Rev.0

33 3.3 Radio transmitter encoder module (MTX +TC9708) Automatic scan mode For this type of mode it is necessary to: 1) set DIP8 at OFF 2) select the requested frequency group by setting the eight dip switches for each module as explained in the following tables: MTXEU03A Group 1 Group 2 Group 3 Group 4 Position DIP 2, 3 e 4 OFF, OFF, OFF ON, OFF, OFF OFF, ON, OFF ON, ON, OFF Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Group 5 Group 6 Group 7 Group 8 Position DIP 2, 3 e 4 OFF, OFF, ON ON, OFF, ON OFF, ON, ON ON, ON, ON Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz In this module, DIPs 5, 6 and 7 do not effect the setting of the frequency group while DIP 1 must be set to OFF. The available frequencies are those belonging to the set group. MAPRMI03 - Rev.0 3-9

34 3.3 Radio transmitter encoder module (MTX +TC9708) MTXUK03A In this module, the DIPs from 2 to 7 are inactive and do not influence in the choice of the frequency group, while DIP 1 must be set at OFF. MTXEU06B In this module, the DIPs from 2 to 7 are inactive and do not influence in the choice of the frequency group, while DIP 1 must be set at ON. MTXAU03A In this module the DIPs from 2 to 7 must be set in order to operate within the permitted frequencies:. DIP 1 DIP 2 DIP 3 DIP 4 DIP 5 DIP 6 DIP 7 DIP 8 OFF ON OFF OFF ON OFF ON OFF 3-10 MAPRMI03 - Rev.0

35 3.3 Radio transmitter encoder module (MTX +TC9708) Manual frequency mode For this type of mode it is necessary to: 1) set DIP8 at ON 2) select the frequency by setting the DIPs from 2 to 7 as explained below as a function of the radio transmitter encoder module: MTXEU03A MAPRMI03 - Rev

36 3.3 Radio transmitter encoder module (MTX +TC9708) MTXUK03A The DIPs that are present make it possible to set other frequencies (see Dip switches page 7) which are not, however, permitted. MTXEU06B The DIPs that are present make it possible to set other frequencies (see Dip switches page 7) which are not, however, permitted. MTXAU03A The DIPs that are present make it possible to set other frequencies (see Dip switches page 7) which are not, however, permitted MAPRMI03 - Rev.0

37 3.4 Interface card (SIC97GP05A) 3.4 Interface card (SIC97GP05A) Electronic card components Led (colour green) Flat cable for the radio transmitter encoder module Led (colour red) Connectors for the actuators Flat cable for the radio transmitter encoder module Buzzer Connector for the bottom control casing Led e buzzer Of the two LEDs on the interface card one is green, the other is red. The green LED blinks slowly during correct operation. If it blinks quickly, this means that the battery is running down and will be completely flat within 15 minutes. The red LED blinks quickly to signal that the battery will be completely flat within 3 minutes. The buzzer is an acoustic signal that activates in particular situations. Operation Green led Red led Buzzer Slow blink normal operation / not operational Fast blink 1st signal of a flat battery 2nd signal of a flat battery not operational (at starting) fixed light / Command inserted during power on operational fixed light for both LEDs frequency has changed operational MAPRMI03 - Rev

38 3.4 Interface card (SIC97GP05A) Replacement Disassembly Assembly 1. Open the transmitting unit ( 3.16). Unscrew the screw that fix the buzzer and the two LEDs to the top control casing. 6. Tighten the screw that clamps the buzzer and the two LEDs to the upper control station casing. Close the transmitting unit ( 3.16). 2. Extract all the connectors from the interface card. 5. Connect all the connectors to the interface card. 3. Unscrew the two screws that clamp the interface card to the upper control casing. 4. Tighten the two screws that clamp the interface card to the upper control casing MAPRMI03 - Rev.0

39 3.4 Interface card (SIC97GP05A) Connectors Symbol 2V5 AU1 AU2 BUZZ CGS COM CRS CSZ F1 F2-F10 G2-G10 GND LEDR LEDV P1 P2 P3 POS RS+ RS- SA SF SF SP SP VBATT VL0 VL1 Z2-Z7 Z8,Z9 Signal 2.5 Vdc Auxiliary Auxiliary (motor start) Buzzer GAS+/GAS- common On/off command common Remote Set Up common Sectioned common START (start command) On/off commands On/off commands Ground (battery negative) Red LED Green LED Joystick 1 enable (if present) Joystick 2 enable (if present) Joystick 3 enable (if present) 5 Vdc Remote Set Up increase Remote Set Up decrease Automatic switching off* SAFETY SAFETY I STOP STOP I Battery voltage (7.2 Vdc) Speed selection Speed selection Proportional commands Auxiliary proportional commands * if automatic switching off is to be deactivated, connect "SA" to "GND". MAPRMI03 - Rev

40 3.5 Transmitting antenna (ANT0 ) 3.5 Transmitting antenna (ANT0 ) Codes Antenna parts ANT005A ANT005B ANT005C ANT012B Transmitting antenna (frequency 433 MHz) Transmitting antenna (frequency 458 MHz) Transmitting antenna (frequency 472 MHz) Transmitting antenna (frequency 870 MHz) antenna cable Replacement Disassembly Assembly 1. Open transmitting unit ( 3.16). Separate the antenna cable from the connector on the radio transmitter encoder module. 5. Insert the antenna cable into the connector of the radio transmitter encoder module. Close the transmitting unit ( 3.16). 4. Fix the antenna to the control station casing, placing a drop of Bostick on each side. 2. Extract the antenna from the bottom control casing. 3. Insert the antenna into its seat in the bottom control casing MAPRMI03 - Rev.0

41 3.6 Double axis Joystick, Penny Giles type 3.6 Double axis Joystick, Penny Giles type Codes Joystick parts A0MANI00E0084 A0MANI00E0085 Double axis joystick proportional, Penny Giles type Double axis joystick proportional with coulisse, Penny Giles type Square clamping nut wiring cable Joystick body Wiring The joystick cables must always be directed as shown in the figure to permit their wiring with the interface card. B A C Connect the joysticks and the interface card as follows: "A" with "1" "B" (if present) with "2" "C" with "3" MAPRMI03 - Rev

42 3.6 Double axis Joystick, Penny Giles type Replacement Disassembly Assembly 1. Open the transmitting unit ( 3.16). After having removed the four symbol plates, unscrew the four screws that are present. 6. Tighten the four screws and cover them with the relative symbol plates. Close the transmitting unit ( 3.16). 2. Extract the square clamping nut. 5. Insert the square clamping nut to block. 3. Extract the joystick body from inside the upper control casing. 4. Insert the joystick body from the inside of the top case of the control station casing: make sure that the bellow does not catch MAPRMI03 - Rev.0

43 3.7 Single axis joystick, Tecnord type 3.7 Single axis joystick, Tecnord type Joystick parts knob gasket bellow clamping screws mechanical washer spacer casing double-sided adhesive gasket joystick body connector Additional information 1) The double-sided adhesive gasket should be positioned under the spacer between the spacer itself and the transmitting unit casing. 2) The spacer should be assembled with the projection upwards, the holes should coinciding perfectly with those of the casing and the joystick body. 3) The metal washer should be inserted into the bellow, pushing it inwards and upwards (it should be near the knob). 4) The bellow must cover the spacer completely: the lower part of the bellow blocks against the projection of the spacer. MAPRMI03 - Rev

44 3.7 Single axis joystick, Tecnord type Replacement Disassembly Assembly 1. Open the transmitting unit ( 3.16). Extract the wiring connector from the one present on the bottom of the joystick body. 6. Insert the wiring connector into the connector present on the bottom of the joystick body. Close the transmitting unit ( 3.16). 2. Unscrew the knob then remove the gasket and the bellow from the joystick. 5. Assemble the gasket and the bellow (into which the washer has been inserted) making sure that the latter covers the spacer. Tighten the knob. 3. Unscrew the two screws that are present, then extract the spacer, the gasket and the metal disc from one side and the joystick body from the other. 4. From inside the upper control station casing insert the joystick body. Return the metal disc, the gasket and the spacer to their places, then tighten the two screws that are present MAPRMI03 - Rev.0

45 3.7 Single axis joystick, Tecnord type Wiring Connect the joysticks and the interface card as follows: C1 with 1 C2 with 1 C3 with 2 C4 with 2 C5 (if present) with 3 C6 (if present) with 3 Each cable kit that exits from an interface card connector divides into two sections. Check the colour of the cables to understand which section should be wired to which joystick. MAPRMI03 - Rev

46 3.8 Double axis joystick, Gessmann type 3.8 Double axis joystick, Gessmann type Codes Joystick parts R0MANI00E03A0 R0MANI00E03B0 double axis proportionale joystick, Gessmann type double axis proportionale joystick, Gessmann type with coulisse knob bellow clamping screws clamping nut double-sided adhesive gasket casing corpo del joystick 3-22 MAPRMI03 - Rev.0

47 3.8 Double axis joystick, Gessmann type Replacement Disassembly 1. Open the transmitting unit( 3.16). Separate the joystick wiring from that of the interface card. Unscrew the knob and remove the bellow. Assembly 6. Insert the bellow, making sure that it is connected to the clamping nut. Tighten the knob. Insert the wiring into the interface card. Close the transmitting unit ( 3.16). 2. Unscrew the four screws that are present. 5. Tighten the four screws to fix the joystick to the transmitting unit casing. 3. Extract the joystick body. 4. Insert the joystick body. INFORMATION FOR THE REPLACEMENT Usually it s not necessary replace the clamping nut. When this replacement is necessary, the double-sided adhesive gasket should be positioned under the clamping nut between the clamping nut itself and the transmitting unit casing. The holes should coincide perfectly with those of the casing, the clamping nut and the joystick body. MAPRMI03 - Rev

48 3.8 Double axis joystick, Gessmann type Wiring The joystick cables must always be directed as shown in the figure to permit their wiring with the interface card. B A C Connect the joysticks and the interface card as follows: "A" with "1" "B" (if present) with "2" "C" with "3" 3-24 MAPRMI03 - Rev.0

49 3.9 Address key 3.9 Address key Description The radio transmitter encoder module is equipped with an address key that contains the address of the radio remote control. This key is: - coloured yellow (grey) - removable - necessary for radio remote control operation - unique, like the serial number given on the label. WARNING! The radio receiving module contains the corresponding address key, which has the same address (and serial number given on the label). This key is, however, coloured grey. DO NOT INTERCHANGE THE TWO AD- DRESS KEYS (the radio remote control would not operate). MAPRMI03 - Rev

50 3.10 STOP pushbutton 3.10 STOP pushbutton Pushbutton parts contacts Replacement clamping nut casing pushbutton body Disassembly 1. Open the transmitting unit ( 3.16). Remove the module ( 3.3). Cut the strip that holds the wiring in position and insert the relative tool into the contact holes. Push heavily and extract the contacts. Assembly 8. Insert the contacts. Fix the wiring with a strip. Assemble the module ( 3.3). Close the transmitting unit ( 3.16). 2. Separate the wiring wires from the contacts. 7. Carry out wiring of the contacts (see Bottom wired control casing page 36) 3. Unscrew completely the clamping nut using the relative tool. 6. Fully tighten the clamping nut. 4. Extract the pushbutton body and the gasket. 5. Extract the pushbutton body and the gasket (which should stay between the pushbutton and the casing) 3-26 MAPRMI03 - Rev.0

51 3.11 Pushbutton kit, TH type 3.11 Pushbutton kit, TH type Pushbutton parts clamping nut pushbutton body casing contact Replacement Disassembly 1. Open the transmitting unit ( 3.16). Remove the module ( 3.3). Cut the strip that holds the wiring in position. Turn the red screw by 90 in a counterclockwise direction. Assembly 8. Turn the red screw by 90 in a clockwise direction. Fix the wiring with a strip. Assemble the module ( 3.3). Close the transmitting unit. ( 3.16). 2. Extract the contacts. Separate the wiring wire from the contacts. 7. Carry out wiring. (see Bottom wired control casing page 36). Insert the contacts. 3. Unscrew completely the clamping nut. 6. Fully tighten the clamping nut. 4. Extract the pushbutton body. 5. Insert the pushbutton body. MAPRMI03 - Rev

52 3.12 Keyswitch selector 3.12 Keyswitch selector Selector parts selector body clamping nut contact clamping wings casing Replacement Disassembly Assembly 1. Open the transmitting unit ( 3.16). Remove the module ( 3.3). Cut the strip that holds the wiring in place. Insert a screwdriver to separate the clamping wings and extract the contacts. 6. Insert the contacts. Fix the wiring with a strip. Assemble the module ( 3.3). Close the transmitting unit ( 3.16). 2. Separate the wiring wires from the contacts. Unscrew the clamping nut using the relative pliers. 5. Tighten the clamping nut using the relative tools. carry out the wiring (see Bottom wired control casing page 36) 3. Extract the selector body. 4. Insert the selector body MAPRMI03 - Rev.0

53 3.13 Toggle switch 3.13 Toggle switch Codes Selector parts R0PULS00E0004 R0PULS00E0014 R0PULS00E0005 R0PULS00E0040 R0PULS00E0006 R0PULS00E0039 R0PULS00E0007 R0PULS00E0042 R0PULS00E0010 R0PULS00E position toggle switch (2 with return) 3-position toggle switch (2 with return), 2 poles 3-position toggle switch 3-position toggle switch, 2 poles 2-position toggle switch (1 with return) 2-position toggle switch (1 with return), 2 poles 3-position toggle switch (1 with return) 3-position toggle switch (1 with return), 2 poles 2-position toggle switch 2-position toggle switch, 2 poles cap symbol plate Symbol carrying plate clamping nut nut spacer Gasket plate for casing gasket selector body MAPRMI03 - Rev

54 3.13 Toggle switch Replacement Disassembly Assembly 1. Open the transmitting unit ( 3.16). After having unsoldered the wiring from the selector contacts, unscrew the cap that contains the clamping nut. 6. Insert the clamping nut into the cap and screw onto the selector. Wire. Close the transmitting unit ( 3.16). 2. Remove the spacer (or the symbol carrying plate). Unscrew the fixing nut. 5. Tighten the clamping nut. Insert the spacer (or the symbol carrying plate). 3. Extract the gasket and the selector body. 4. Insert the gasket and the selector body. Wiring For wiring, weld the cable of the command to the contact which is opposite to the selection and the common cable to the central contact. Fx command Fy command Contact for Fy command Contact for Fx command Contact for the common 3-30 MAPRMI03 - Rev.0

55 position rotative switch position rotative switch Selector parts cap knob clamping nut casing gasket selector body gasket connector Resistor setting The selector must be set by removing the resistors, according to whether the configuration requires a central or lateral 0 position. Central 0 position Lateral 0 position Remove resistors R1 and R2. Remove resistors R2 and R4. R1 e R2 R3 e R4 MAPRMI03 - Rev

56 position rotative switch Replacement Disassembly Assembly 1. Open the transmitting unit ( 3.16). Cut the strap. Unsolder the wiring from the connector. 7. Insert the wiring into the connector. Fix the wiring using a strap. Close the transmitting unit ( 3.16). 2. Remove the cap. Loosen the knob locking nut using the relative pliers. Extract the knob. 6. Tighten the knob using the relative pliers (the white line must be positioned at 0). Insert the cap (the black line must coincide with the white line). 3. Remove the nut that blocks the selector body and extract the latter. 5. Insert the selector body with the two gaskets. Fix by tightening the nut. 4. Insert the two gaskets into the selector body MAPRMI03 - Rev.0

57 3.15 Potentiometers 3.15 Potentiometers A0RESI04E0038 Potentiometer parts nut gasket potentiometer body clamping nut casing Replacement Disassembly Assembly 1. Open the transmitting unit ( 3.16). Unsolder the wiring. Unscrew the nut and extract the clamping nut. 4. Insert the clamping nut and tighten the nut. Weld the wiring. Close the transmitting unit. ( 3.16). 2. Extract the potentiometer body and the gasket. 3. Insert the gasket into the potentiometer body and then the potentiometer body into the hole of the transmitting unit casing. Wiring C A B MAPRMI03 - Rev

58 3.15 Potentiometers R0RESI04E0041 Potentiometer parts gaskets nut knob potentiometer body casing clamping nut cap Replacement Disassembly Assembly 1. Open the transmitting unit ( 3.16). Remove the cap. Loosen the knob locking nut using the relative pliers. Extract the knob. 6. Using the relative pliers tighten the knob and insert the cap (the black line must coincide with the white line). Close the transmitting unit ( 3.16). 2. Unscrew the nut and extract the clamping nut. 5. Insert the clamping nut and tighten the nut. 3. Unsolder the wiring and extract the potentiometer body with the three gaskets. 4. Weld the wiring. Insert the three gaskets into the potentiometer body, and the potentiometer body into the hole in the transmitting unit casing MAPRMI03 - Rev.0

59 3.15 Potentiometers Wiring b C D MAPRMI03 - Rev

60 3.16 Bottom wired control casing 3.16 Bottom wired control casing Codici Opening and closing R0POCO16E03A0 R0POCO16E04A0 R0POCO12E06A0 Disassembly Bottom wired control casing Bottom wired control casing for cable control Bottom wired control casing for IR START UP Assembly Unscrew the four screws that keep the transmitting unit closed. Remove the battery. 6. Tighten the four screws. Insert the battery. 2. Open the transmitting unit as a book (bottom casing of the control casing on the right). 5. Close the transmitting unit. 3. Extract the flat cable from the radio transmitter encoder module and the connector from the interface card. 4. Insert the flat cable into the radio transmitter encoder module and the connector into the interface card MAPRMI03 - Rev.0

61 3.16 Bottom wired control casing Replacement Disassembly Assembly 1. Open the transmitting unit. Disconnect the antenna cable from the connector present in the module. 6. Insert the antenna cable into the connector of the radio transmitter encoder module. Close the transmitting unit. 2. Unscrew the four screws that fix the radio transmitter encoder module to the bottom control station casing. 5. Tighten the four screws to fix the radio transmitter encoder module to the bottom control station casing. 3. Extract the radio transmitter encoder module. 4. Insert the radio transmitter encoder module into the new bottom control station casing. MAPRMI03 - Rev

62 3.16 Bottom wired control casing Wiring R0POCO16E03A MAPRMI03 - Rev.0

63 3.16 Bottom wired control casing R0POCO16E04A0 (bottom wired control station for cable control) MAPRMI03 - Rev

64 3.16 Bottom wired control casing R0POCO12E06A0 (bottom wired control casing for IR START UP) 3-40 MAPRMI03 - Rev.0

65 3.17 Bottom casing 3.17 Bottom casing Codes R0POCO16P12A0 R0POCO16P13A0 R0POCO12P06A0 Bottom casing Bottom casing for cable control Bottom casing for IR START UP MAPRMI03 - Rev

66 3.18 Upper casing 3.18 Upper casing Codes R0POCO16P03A0 R0POCO16P06A0 R0POCO16P07A0 R0POCO16P08A0 R0POCO16P09A0 R0POCO16P10A0 Upper casing with 2 holes for Gessmann joystick Upper casing with 3 holes for Gessmann joystick Upper casing with 2 holes for Penny Giles joystick Upper casing with 3 holes for Penny Giles joystick Upper casing with 4 holes for Tecnord joystick Upper casing with 6 holes for Tecnord joystick F0POCO16P03A0 F0POCO16P06A0 F0POCO16P07A0 F0POCO16P08A0 F0POCO16P09A0 F0POCO16P10A0 To order the command panel relative to the casing, supply the serial number of the radio remote control MAPRMI03 - Rev.0

67 3.19 Technical data and findings 3.19 Technical data and findings Technical data Number of available commands... for MA... 6 analog + 12 on/off + start + stop for PRO-M analog + 12 on/off + start + stop Antenna... integrated Type of modulation... GFSK Power... < 10mW (433 MHz)...< 5 mw (870 MHz) Findings Power supply...battery pack NiMH 7,2 V Ah Turn off voltage... 6 V Autonomy with fully charged battery (at 20 C)... about 10 ore Time of 1 prewarning time... about 15 minutes Time of 2 prewarning time... about 3 minutes Housing... PA6 fv 20% Protection grade... (173x160x236) mm Weight kg Fixing of the... to... No. screws Paragraph Bottom control casing (or casing) Upper control casing (or casing) 4 (M 4x8) 3.16 radio transmitter encoder module Bottom control casing 4 (M 2.9x6.5) 3.3 interface card Upper control casing (or casing) 2 (M 3x6) 3.4 interface card Upper control casing (or casing) 1 (M 2.9x9.5) 3.4 MAPRMI03 - Rev

68 3.19 Technical data and findings 3-44 MAPRMI03 - Rev.0

69 PRO-M receiving unit index 4 PRO-M receiving unit Receiving unit diagnostic Exploded view and spare parts Radio receiver module (MRX 0 ) Receiver decoder module (RD97-00A) Analogue receiver module (RI97-08_0ZA) Bus card (RI97BUS01ZA) Master board (SBR97DC08) Address key Receiving case Antenna Antenna with cable, length 5 m Antivibration supplort kit Technical data and findings MAPRME04 - Rev.0 4-1

70 PRO-M receiving unit replacements index Replacement of radio receiver module Replacement of receiver decoder module Replacement of analogue receiver module Replacement of BUS card Replacement of master board Replacement of receiving case Replacement of antenna Replacement of antenna with cable, leght 5 m Assembly of antenna with cable, lenght 5 m PRO-M receiving unit programmings index Programming of the frequency at automatic scan mode Programming of the frequency at manual frequency mode Programming of the analogue radio module (REMOTE SET UP) setting Programming for activate two commands contemporary Programming for activate SAFETY Programming of passive emercency time Programming for activate FLOW MAPRME04 - Rev.0

71 4 PRO-M receiving unit The PRO-M receiving unit can only be installed on hoisting and moving equipment installed on vehicles where there is a battery power supply. The following applications are therefore not permitted: - machines supplied by AC - machines where the DC supply does not come from a battery. In addition, the receiving unit cannot be installed on: - machines installed in environments where apparatus with flameproof characteristics are needed. - machines for moving, lifting and transporting people. MAPRME04 - Rev.0 4-3

72 4.1 Receiving unit diagnostic 4.1 Receiving unit diagnostic Is the POWER light lit? Disconnect the power from the receiving unit. Is the F1 fuse integral? Check the power supply connections. Replace F1 ( 4.7) Does the system now operate correctly? Has the internal wiring of the receiving unit been carried out correctly? Carry out the correct wiring (see technical data sheet) Look at the BUS card diagnostic ( 4.6). Does the system start correctly? Replace the BUS card ( 4.7) Does the system start correctly? CALL SERVICE (continues on the next page) 4-4 MAPRME04 - Rev.0

73 4.1 Receiving unit diagnostic Is the ENABLE light lit? Look the BUS card diagnostic ( 4.6) Does the system start correctly? Look radio module diagnostic ( 4.3) CALL SERVICE Does the system start correctly? Replace the address key. Does the system start correctly? Disconnect the power from the receiving unit. Is the F2 fuse integral? Replace F2 ( 4.7) Is the F3 fuse integral? Has the internal wiring of the receiving unit been carried out correctly? Carry out the correct wiring (see technical data sheet) Replace F3 ( 4.7) Replace analogue module diagnostic ( 4.5) Does the system start correctly? Replace master board ( 4.7) Does the system start correctly? CALL SERVICE MAPRME04 - Rev.0 4-5

74 4.2 Exploded view and spare parts 4.2 Exploded view and spare parts Exploded view MAPRME04 - Rev.0

75 4.2 Exploded view and spare parts Spare parts N Codice Descrizione 4.10 F0ANTE00E24A0 Receiving unit antenna (frequency 433 MHz) 4.10 F0ANTE00E32A0 Receiving unit antenna (frequency 870 MHz) 4.7 F0BASE00E55A0 SBR97DC08 master board 4.9 F0CASS00P22A0 Receiving case 4.5 F0INRI00E45A0 RI97-08V0ZA analogue receiver module with voltage outputs 4.5 F0INRI00E46A0 RI97-08P0ZA analogue receiver module with PWM outputs 4.6 F0INRI00E47A0 RI97BUS01ZA BUS card 4.4 F0RIDE00E10A0 RD97-00A receiver decoder module 4.3 F0RIRA00E11A0 MRXEU03A radio receiver module (frequency 433 MHz) 4.3 F0RIRA00E11D0 MRXUK03A radio receiver module (frequency 458 MHz) 4.3 F0RIRA00E14A0 MRXEU06B radio receiver module (frequency 870 MHz) 4.11 G0ANTE00E10A0 Antenna with cable, length 5 m G0ANVI00M0002 Antivibration support kit "N " is the paragraph number which refers to the spare part. Warning No voltage should be present when carrying out any internal operations (replacement or programming) on the receiving unit, therefore make sure that the power is disconnected from the receiving unit before proceeding. MAPRME04 - Rev.0 4-7

76 4.3 Radio receiver module (MRX 0 ) 4.3 Radio receiver module (MRX 0 ) Codes MRXEU03A MRXUK03A MRXEU06B MRXAU03A Radio receiver module frequency 433 MHz Radio receiver module frequency 458 MHz (module for England) Radio receiver module frequency 870 MHz Radio receiver module frequency 472 MHz (module for Australia) Always make sure that the frequencies at which the radio receiving module operates are permitted in the country where the radio remote control is to be used. Module components Led 1 (green colour) Led 2 (green colour) Led 3 (yellow colour) Dip switches BUS card connector Antenna cable connector Leds The three LEDs that are present indicate if the radio receiving module: - is being supplied correctly (LED 1) - is receiving a radio signal at the operating frequency (LED 2) - is scanning the frequencies (when LED 3 blinks) Dip switches The eight dip switches present in the radio receiving module define the frequency operation mode (automatic scan or manual selection) and the operating frequency itself: : MHz (sempre OFF) MHz MHz Frequency value for each MHz DIP in the ON position MHz MHz MHz ON = manual selection OFF = automatic scan The radio receiving module dip switches must always be set in the same manner as the dip switches of the radio transmitter encoder module. 4-8 MAPRME04 - Rev.0

77 4.3 Radio receiver module (MRX 0 ) Diagnostic Is LED 1 lit? Replace the radio receiver module. Does the system start? Is the light of LED 2 steady and is the transmitting unit switched off? Carry out the frequency change procedure. Does the system start? Replace the radio receiver module and the radio transmitter encoder module. If the system does not start, CALL SERVICE Is the LED 2 light steady and the transmitting unit powered? Is the LED 3 light steady? Replace the radio receiving module. Does the system start? Is the LED 3 light blinking and is DIP 8 at the OFF position? Carry out the frequency change procedure. Does the system start? Check the receiver decoder module diagnostic ( 4.4) Check the connections of the external antenna (if present). Does the system start? Replace the radio receiving module and the radio transmitter encoder module If the system does not start, CALL SERVICE MAPRME04 - Rev.0 4-9

78 4.3 Radio receiver module (MRX 0 ) Replacement Disassembly Assembly 1. Unscrew the four screws that fix the BUS card to the master board. 6. Tighten the four screws to fix the BUS card to the master board. 2. Extract the BUS card from the receiving case and separate the antenna cable from the connector that is present in the radio receiving module. 5. Insert the antenna cable that is present into the radio receiving module connector. 3. Widen the two guides and extract the radio receiving module (third from the top) 4. After having set the dip switches, insert the new radio receiving module into its connector and into the seats of the BUS card guides MAPRME04 - Rev.0

79 4.3 Radio receiver module (MRX 0 ) Automatic scan mode For this type of mode it is necessary to: 1) set DIP8 at OFF 2) select the requested frequency group by setting the eight dip switches for each module as explained in the following tables: MTXEU03A Group 1 Group 2 Group 3 Group 4 Position DIP 2, 3 e 4 OFF, OFF, OFF ON, OFF, OFF OFF, ON, OFF ON, ON, OFF Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Group 5 Group 6 Group 7 Group 8 Position DIP 2, 3 e 4 OFF, OFF, ON ON, OFF, ON OFF, ON, ON ON, ON, ON Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz In this module, DIPs 5, 6 and 7 do not effect the setting of the frequency group while DIP 1 must be set to OFF. The available frequencies are those belonging to the set group MAPRME04 - Rev

80 4.3 Radio receiver module (MRX 0 ) MTXUK03A In this module, the DIPs from 2 to 7 are inactive and do not influence in the choice of the frequency group, while DIP 1 must be set at OFF. MTXEU06B In this module, the DIPs from 2 to 7 are inactive and do not influence in the choice of the frequency group, while DIP 1 must be set at ON. MTXAU03A In this module the DIPs from 2 to 7 must be set in order to operate within the permitted frequencies:. DIP 1 DIP 2 DIP 3 DIP 4 DIP 5 DIP 6 DIP 7 DIP 8 OFF ON OFF OFF ON OFF ON OFF 4-12 MAPRME04 - Rev.0

81 4.3 Radio receiver module (MRX 0 ) Manual frequency mode For this type of mode it is necessary to: 1) set DIP8 at ON 2) select the frequency by setting the DIPs from 2 to 7 as explained below as a function of the radio transmitter encoder module: MRXEU03A MAPRME04 - Rev

82 4.3 Radio receiver module (MRX 0 ) MRXUK03A The DIPs that are present make it possible to set other frequencies (see Dip switches page 8) which are not, however, permitted. MRXEU06B The DIPs that are present make it possible to set other frequencies (see Dip switches page 8) which are not, however, permitted. MRXAU03A The DIPs that are present make it possible to set other frequencies (see Dip switches page 8) which are not, however, permitted MAPRME04 - Rev.0

83 4.4 Receiver decoder module (RD97-00A) 4.4 Receiver decoder module (RD97-00A) Module components Led 2 (green colour) Led 3 (green colour) Led 4 (red colour) Led 1 (green colour) Address key connector BUS card connector Diagnostic Is LED 4 lit? Is the power supply voltage of the receiving unit correct? Correctly power the receiving unit. Does the system start? Return to the receiving unit diagnostic. ( 4.1) Replace the receiver decoder module. Does the system start? Replace the master board ( 4.7) Does the system start? Return to the receiving unit diagnostic. ( 4.1) Leds MAPRME04 - Rev.0 The four LEDs present on the receiver decoder module indicate: LED 1 (green) ON : module being powered correctly with a steady voltage of between 9 and 15 Vdc OFF: module being powered incorrectly LEDs 2 and 3 (green) ON: module operating correctly 4-15

84 4.4 Receiver decoder module (RD97-00A) Replacement OFF: module not operating correctly These two LEDs must blink during the test phase after power on and before true operation. LED 4 (red) ON: the module is signalling the presence of a fault in the system OFF: the module is operating correctly Disassembly Assembly 1. Unscrew the four screws that fix the BUS card to the master board. 8. Tighten the four screws to fix the BUS card to the master board. 2. Extract the BUS card from the receiving case and separate the antenna cable from the connector that is present in the radio receiver module. 7. Insert the antenna cable that is present into the radio receiver module connector. 3. Widen the two guides and extract the receiver decoder module (second from the top) 6. Insert the new receiver decoder module into its respective connector and into the seats of the BUS card guides. 4. Extract the address key from the receiver decoder module that is to be replaced. 5. Insert the address key into the new receiver decoder module MAPRME04 - Rev.0

85 4.5 Analogue receiver module (RI97-08_0ZA) 4.5 Analogue receiver module (RI97-08_0ZA) Codes RI97-08V0ZA RI97-08P0ZA Analogue receiver module with voltage outputs Analogue receiver module with PWM outputs Module components Connector for the auxiliary proportional outputs Rotary switch Green led Connector for the proportional output Reset pushbutton Connector for the power supply Data memory Connector for the calibration key Connector for connection to the BUS card Calibration key Information about module 1) Never leave the K1 calibration key inserted during radio remote control use. The key is only needed during the calibration phase and, when inserted, only one proportional command can be activated at a time. 2) The proportional outputs of RI97-08 module are programmed at the values given on the relevant technical data sheet. 3) To keep the same settings in case of module replacement, move the K2 memory from the old module to the new one. Welding points Some welding points are present on the analogue receiver module: PAD STATE DESCRIPTION S3 stabilised voltage S3 in step voltage S4 RI97-08P0ZA configuration S4 RI97-08V0ZA configuration S3 is the right-hand welding point, S4 the left one The S4 welding point must be closed in RI97-08P0ZA modules, while it must be open in the RI97-08V0ZA module. To set S3 please keep in mind the following: Stabilised voltage: the voltage of the module outputs are always related to an absolute voltage value. In step voltage: the module output voltages are related to the true power supply values. MAPRME04 - Rev

86 4.5 Analogue receiver module (RI97-08_0ZA) PAD STATE DESCRIPTION S1 RI97-08V0ZA configuration S1 RI97-08P0ZA configuration The S1 setting can at times be different from what is indicated above. Check the current setting given in the technical data sheet, and during replacement verify that the new module is set in the same manner as the one to be replaced. Replacement Disassembly Assembly 1. Unscrew the four screws that fix the BUS card to the master board. 6. Tighten the four screws to fix the BUS card to the master board. 2. Extract the BUS card from the receiving case and separate the antenna cable from the connector that is present in the radio receiver module. 5. Insert the antenna cable into the radio receiver module connector. 3. Widen the two guides and extract the analogue receiver module (first from the top) 4. Insert the new analogue receiver module into the respective connector and into the BUS card guide seats MAPRME04 - Rev.0

87 4.5 Analogue receiver module (RI97-08_0ZA) Preparation for setting Rotary switch setting 1. Make sure that the transmitting unit is switched off. 2. Disconnect the power from the receiving unit. 3. Open the receiving unit and insert the K1 settings key into the C4 connector. 4. Power the receiving unit. ATTENTION: From this moment onwards do not touch the receiving unit until setting up has been completed (otherwise you risk losing the settings that have already been set) 5. Turn the transmitting unit ignition key to "I" and press the START pushbutton. 6. Turn the starting key to the " " position (REMOTE SET UP). 7. Select the parameters to be set using the rotary switch S, which can be found on the RI97-08 module, and the RPM+/- selector, which is present on the transmitting unit (+ increases the value being set, - decreases it). Setting modules with voltage outputs Setting modules with PWM outputs MAPRME04 - Rev.0 In modules with voltaged outputs it is possible to set positions 1, 2, 3, 4 and 5. In modules with current outputs (PWM) it is possible to set positions 0, 1, 3 and 4. When the rotary switch S is at 1 POSITION, it is possible to regulate the maximum and minimum voltage values of the two semiaxes of a joystick. Proceed as follows: 1. To set the maximum value, take the joystick to the maximum range of the semiaxis to be calibrated. Use the toggle switch RPM +/- to modify the value while maintaining same joystick position. 2. To set the minimum value, take the joystick just out of the rest position of the semiaxis to be calibrated. Use the toggle switch RPM +/- to modify the value while maintaining same joystick position. When the rotary switch S is at 2 POSITION, it is possible to regulate the voltage value which corresponds to the mechanical rest position of the joystick. Normally, this value shouldn t be modified. Proceed as follows: - take any joystick out of the rest position - use the toggle switch RPM +/- to modify the value while maintaining same joystick position. When the rotary switch S is at 3 and 4 POSITION, it is possible to regulate the maximum and minimum voltage values of auxiliary outputs Z8 and Z9 respectively. Proceed as follows: 1. To set the maximum value, turn the Z8 (or Z9) command knob (present in the transmitting unit) fully clockwise. Use the toggle switch RPM +/- to modify the value while maintaining same knob position. 2. To set the minimum value, turn the Z8 (or Z9) command knob (present in the transmitting unit) fully counterclockwise. Use the toggle switch RPM +/- to modify the value while maintaining same knob position. Semiaxis direction is inverted when the rotary switch S is at 5 POSITION. Proceed as follows: - take the joystick of the axis to be inverted out of the rest position - while maintaining this situation, use the toggle switch RPM +/- on the transmitting unit. Move it to + in order to invert the semiaxis direction or to - in order to reset the semiaxis direction. When the rotary switch S is at 0 POSITION, the PWM (current) signal frequency can be adjusted. Normally this value shouldn t be modified. If necessary, proceed as follows: - take one joystick out of the rest position 4-19

88 4.5 Analogue receiver module (RI97-08_0ZA) - use the toggle switch RPM +/- to modify the value while maintaining same joystick position. When the rotary switch S is at 1 POSITION, it is possible to regulate the maximum and minimum voltage (or current) values of the two semiaxes of a joystick. Proceed as follows: 1. To set the maximum value, take the joystick to the maximum range of the semiaxis to be calibrated. Use the toggle switch RPM +/- to modify the value while maintaining same joystick position. 2. To set the minimum value, take the joystick just out of the rest position of the semiaxis to be calibrated. Use the toggle switch RPM +/- to modify the value while maintaining same joystick position. When the rotary switch S is at 3 and 4 POSITION, it is possible to regulate the maximum and minimum voltage values of auxiliary outputs Z8 and Z9 respectively. Proceed as follows: 1. To set the maximum value, turn the Z8 (or Z9) command knob (present in the transmitting unit) fully clockwise. Use the toggle switch RPM +/- to modify the value while maintaining same knob position. 2. To set the minimum value, turn the Z8 (or Z9) command knob (present in the transmitting unit) fully counterclockwise. Use the toggle switch RPM +/- to modify the value while maintaining same knob position. Saving the settings Important notes about setting 8. Switch off the transmitting unit to save the settings. 9. Disconnect power from the receiving unit. 10. Extract the K1 settings key. 11. Close the receiving unit and power it. If the joystick is moved out of its rest position during setting, the horn/alarm sounds for 0.5 seconds, indicating that you are in the minimum setting area. Each single position of the speed selector present on the transmitting unit must be set. Output values reset To reset the initial proportional output values (i.e. those given in the technical data sheet), with calibration key K1 inserted, just keep reset button P pressed until the green led L stops flashing and remains lit MAPRME04 - Rev.0

89 4.6 Bus card (RI97BUS01ZA) 4.6 Bus card (RI97BUS01ZA) Card components Connector for the receiver decoder module Connector for the radio receiver module Connector for the analogue receiver module Connector for the master board Module fixing guides Diagnostic Is the BUS card connected to the master board correctly? Correctly insert the BUS card into the connector (using the screws) Does the system start? Is at least one of the lights of the decoder, radio and analogue modules lit? Replace the BUS card. Does the system start correctly? Are all three receiver modules inserted correctly into the BUS card? Correctly insert the BUS card into the connector. Does the system start? Return to the receiving unit diagnostic. ( 4.1) MAPRME04 - Rev

90 4.6 Bus card (RI97BUS01ZA) Replacement Disassembly Assembly 1. Unscrew the four screws that fix the BUS card to the master board. 8. Tighten the four screws to fix the BUS card to the master board. 2. Extract the BUS card from the receiving case and separate the antenna cable from the connector that is present in the radio receiver module. 7. Insert the antenna cable into the radio receiver module connector. 3. Widen the two guides and extract the three receiver modules, separating them from the BUS card. 6. Insert the three receiver modules into their respective connectors and into the slots (present on the two guides) of the BUS card. 4. Extract the four screws that are present in the guides of the BUS card that is to be replaced. 5. Insert the four screws into the holes present in the guides of the new BUS card (check the settings) MAPRME04 - Rev.0

91 4.6 Bus card (RI97BUS01ZA) Connectors The three receiver modules should be inserted into the connectors in the following manner: Connector for the analogue receiver module Connector for the receiver decoder module Connector for the radio receiver module The layout of the connector pin signals that are present is as follows: (RESERVED: pin for a control signal). Connector for electrical connection to the master board Connector for electrical connection to the receiver modules. MAPRME04 - Rev

92 4.6 Bus card (RI97BUS01ZA) Signalling LEDs When relays relative to sent commands are activated on the master board, the corresponding LED illuminates. The POWER and ENABLE LEDs are also visible externally on the receiving unit. They signal: POWER: the presence of power in the receiving unit ENABLE: radio link between the transmitting and the receiving units. Dip switches DIP POSITION DESCRIPTION 1 ON F2 activated by G2 and G2 activated by F2 1 OFF F2 and G2 indipendent from each other 2 ON F3 activated by G3 and G3 activated by F3 2 OFF F3 and G3 indipendent from each other 3 ON F4 activated byg4 and G4 activated by F4 3 OFF F4 and G4 indipendent from each other 4 ON F5 activated by G5 and G5 activated by F5 4 OFF F5 and G5 indipendent from each other DIP POSITION DESCRIPTION 1 ON F6 activated by G6 and G6 activated by F6 1 OFF F6 and G6 indipendent from each other 2 ON F7 activated by G7 and G7 activated by F7 2 OFF F7 and G7 indipendent from each other 4-24 MAPRME04 - Rev.0

93 4.6 Bus card (RI97BUS01ZA) Welding points PAD STATE DESCRIPTION S3 FLOW activated by F2-G2 S3 F2 and G2 do not activated FLOW S4 FLOW activated by F3-G3 S4 F3 and G3 do not activated FLOW S5 FLOW activated by F4-G4 S5 F4 and G4 do not activated FLOW S6 FLOW activated by F5-G5 S6 F5 and G5 do not activated FLOW S7 FLOW activated by F6-G6 S7 F6 and G6 do not activated FLOW S8 FLOW activated by F7-G7 S8 F7 and G7 do not activated FLOW The following standard programme is pre-set by Autec: S3 S8 CLOSED PAD STATE DESCRIPTION S15 F8 activated by G8 S15 F8 indipendent from G8 S16 F9 activated by G9 S16 F9 indipendent from G9 S17 F10 activated by G10 S17 F10 indipendent from G10 S18 F11 activated by G11 S18 F11 indipendent from G11 S19 F12 activated by G12 S19 F12 indipendent from G12 S20 F13 activated by G13 S20 F13 indipendent from G13 The following standard programme is preset by Autec: S15 S20 OPEN MAPRME04 - Rev

94 4.6 Bus card (RI97BUS01ZA) PAD STATE DESCRIPTION S1 SAFETY activated by F2 G7 S1 SAFETY activated by F1 G13 S2 Passive emercency time = 1.5 s S2 Passive emercency time = 0.5 s The following standard programme is pre-set by Autec: S1 CLOSED and S2 OPEN 4-26 MAPRME04 - Rev.0

95 4.7 Master board (SBR97DC08) 4.7 Master board (SBR97DC08) Board components Connector for the BUS card Holes for fixing the master board to the receiving case BUS card fixing holes BUS card fixing holes Holes for fixing the master board to the receiving case Fuses Holes for fixing the master board to the receiving case Replacement Diassembly Assembly 1. Unscrew the four screws that fix the BUS card to the master board. 6. Tighten the four screws to fix the BUS card to the master board. 2. Extract the BUS card from the receiving case and separate the antenna cable from the connector that is present in the radio receiver module. 5. Insert the antenna cable into the radio receiver module connector. 3. Unscrew the eight screws and extract the master board from the receiving case. 4. Insert the new master board and tighten the eight screws. MAPRME04 - Rev

96 4.7 Master board (SBR97DC08) Connector The layout of the signals on the connector pins is as follows: (RESERVED: pin for a control signal). Fuses Name Function Characteristics F1 F2 F3 POWER SUPPLY circuit protection STOP circuit protection SAFETY Protezione del circuito 4A (32 Vdc, autofuse) 10A (32 Vdc, autofuse) 10A (32 Vdc, autofuse) AUTOFUSE: fuses for automotives F1 F2 F MAPRME04 - Rev.0

97 4.7 Master board (SBR97DC08) Connectors for wiring +: positive -: negative NC: normally closed NO: normally open C: common Power: power supply (8 30 Vdc) Stop: command which blocks the receiver unit and, as a result, the machine Safety: safety function which protects the system from involuntary movements caused by possible radio remote control failure. This function constantly controls the zero position (rest) of the movement command actuators. Flow: function which commands the solenoid valve that lets pressurised oil into the hydraulic circuit of the main distributor. The movement commands normally activate this function. TS: (TIMED STOP) command used for switching off the auxiliary or diesel motor of the machine. The motor remains active for 10 seconds after the STOP command has been activated. CD: common recovery diodes F e G : movement and selection commands MAPRME04 - Rev

98 4.8 Address key 4.8 Address key Description The receiver decoder module is equipped with an address key that contains the address of the radio remote control. This key is: - coloured grey - removable - necessary for radio remote control operation - unique, like the serial number given on the label. WARNING! The radio encoder trasmitter module contains the corresponding address key, which has the same address (and serial number given on the label). This key is, however, coloured yellow. DO NOT INTERCHANGE THE TWO AD- DRESS KEYS (the radio remote control would not operate) MAPRME04 - Rev.0

99 4.9 Receiving case 4.9 Receiving case Case components POWER light Closing screw ENABLE light Identification plate Technical data plate Closing screws Closing screw Antenna cable Multiple plug Lights The POWER and ENABLE lights signal: POWER: the presence of power supply in the receiving unit ENABLE: radio link between the transmitting and receiving units When the receiving unit is powered, operation is correct if: - POWER and ENABLE are lit when the transmitting unit is started - POWER is lit and ENABLE switched off when the transmitting unit is switched off. Antenna cable The receiving case holds a cable for the antenna which connects the radio receiver module to the antenna outside the case. This cable should be connected to the radio receiver module connector by way of the hole present on the BUS card. MAPRME04 - Rev

100 4.9 Receiving case Replacement If the receiving case is to be replaced: - quote the serial number when ordering a new one - make sure that the plates on the new receiving case are the same as those on the replaced receiving case. Disassembly Assembly 1. Loosen the four screws that keep the receiving case closed. 8. Tighten the four screws to close the receiving case (first the two upper screws, then the two lower ones). 2. Unscrew the four screws that fix the BUS card to the master board. 7. Tighten the four screws to fix the BUS card to the master board. 3. Extract the BUS card from the receiving case and separate the antenna cable from the connector that is present in the radio receiver module. 6. Insert the antenna cable into the radio receiver module connector. 4. Loosen the eight screws that are present and extract the master board from the receiving case that is to be replaced. 5. Insert the master board into the new receiving case and fix it using the eight screws MAPRME04 - Rev.0

101 4.10 Antenna 4.10 Antenna Codes F0ANTE00E24A0 F0ANTE00E32A0 antenna (frequency 433 MHz) antenna (frequency 870 MHz) Replacement To separate the antenna from the receiving unit, rotate it in an anti-clockwise direction. To connect the antenna to the receiving unit, rotate it in a clockwise direction. to connect to separate The antenna must never come into contact with metallic parts. The antenna must always be vertical. Connection If the antenna is to create a radio link between the transmitting unit and the receiving unit, the cable inside the receiving case must be connected to the radio receiver module (see Antenna cable page 31). MAPRME04 - Rev

102 4.11 Antenna with cable, length 5 m Antenna with cable, length 5 m. Indications for installation If the receiving unit is covered or shielded by metal structures or installed inside electric panels, use the antenna with the 5 metre cable. Install it in a position that favours reception of the signals emitted by the transmitting unit. The antenna must always be assembled on a metal support surface, but the antenna stylus must never come into contact with metallic parts. Replacement Disassembly Assembly 1. With the receiving unit disconnected from the power supply, assemble the different parts of the antenna, fixing them to a metal support surface. 4. Disassemble the antenna, separating the different parts from the support surface. 2. Insert one end of the cable into the antenna connector and the other into the relative receiving case connector. 3. Disconnect the power from the receiving unit. Extract the ends of the cable from the antenna connector and the relative receiving case connector MAPRME04 - Rev.0

103 4.12 Antivibration supplort kit 4.12 Antivibration supplort kit Assembly To reduce the effect of vibrations on the receiving unit, always use antivibration supports. These supports can be assembled in two different ways: 1) DRILLING AND THREADING THE SUPPORT PANEL Support panel Receiving unit SUPPORT Fixing nut Drilling particulars HOLE: thread DIAMETER: 5 mm TAPPING: M6 DATA NUMBER: 1 2) CONTROL PANEL DRILL HOLE (PASS THROUGH) WITH THE USE OF AN AD- DITIONAL NUT Additional fixing nut Support panel SUPPORT Receiving unit Fixing nut Drilling particulars HOLE: drilling DIAMETER: 6.5 mm TAPPING: / DATA NUMBER: 2 MAPRME04 - Rev

104 4.13 Technical data and findings 4.13 Technical data and findings Technical Data Power Vdc (40 W) Antenna...external (dedicated) Max switching capacity of STOP and SAFETY contacts A (30 Vdc) Max switching capacity of movement commands contacts... 4 A (30 Vdc) Max switching capacity of selection commands contacts... 6 A (30 Vdc) Sensitivity receiver... 0,5 µv per 20 db SINAD Housing... PA6 fg 20% Minimum protection grade... IP65 Dimensions...(180x230x95) mm Weight kg Drilling template... A = 148 mm B = 116 mm C = 253 mm D = 253 mm Findings Clamp of... to... n screws Paragraph lower part of the receiving case receiving case cover 4 (M5x15) 4.9 master board lower part of the receiving case 8 (M4x10) 4.7 BUS card master board 4 (M3x20) MAPRME04 - Rev.0

105 C26 PRO MA receiving unit index 5 C26 PRO MA receiving unit Receiving unit diagnostic Exploded view and spare parts Radio receiver module (MRX 0 ) Receiver decoder module (RD97-00A) Analogue receiver module (RI97-08_0ZA) Relay card (SR97R0 ) relay card (RI97R03S1 ) DC master board (SBR97DC ) AC master board (SBR97AC ) Power supply card (SBA97V ) Address keys Receiving case Internal antenna at 870 MHz External antenna with support External antenna with cable Cable for wiring with recovery diodes Technical data and findings MAPRME05 - Rev.0 5-1

106 C26 PRO MA receiving unit replacements index Replacement of radio receiver module Replacement of receiver decoder module Replacement of analogue receiver module Replacement of relay card Replacement of 3-relay card Replacement of DC master board Replacement of AC-master board Replacement of power supply card Replacement of receiving case Replacement of internal antenna at 870 MHz Replacement of external antenna with support C26 PRO MA receiving unit programmings index Programming of the frequency at automatic scan mode Programming of the frequency at manual frequency mode Programmaing of the analogue radio module (REMOTE SET UP) setting Programming of the relay card Programming of DC-master board Programming for activate SAFETY (DC-master board) Programming of passive emercency time (DC-master board) Programming of AC-master board Programming for activate SAFETY (AC-master board) Programming of passive emercency time (AC-master board) Use of cable for wiring with recovery diodes MAPRME05 - Rev.0

107 5 C26 PRO MA receiving unit The C26 PRO MA receiving unit can only be installed on hoisting and moving equipment with an AC or DC power supply. This receiving unit cannot be installed in areas where apparatus with flameproof characteristics is necessary. Other applications (such as manoeuvring locomotives, or machines that lift people, crates and aerial platforms...) can be considered but the additional risks must be analysed to evaluate if the machine can be radio remote controlled. This risk analysis is the responsibility of whoever puts the radio remote controlled machine onto the market or whoever decides upon radio remote control installation and use. MAPRME05 - Rev.0 5-3

108 5.1 Receiving unit diagnostic 5.1 Receiving unit diagnostic Is the POWER light lit? Disconnect the power from the receiving unit. Is the F1 fuse integral? Replace F1 ( 5.8) o ( 5.9) Check the power supply. Does the system now operate correctly? Has the internal wiring of the receiving unit been carried out correctly? Carry out the correct wiring (see technical data sheet) Look at the master board diagnostic ( 5.8) o ( 5.9) Does the system start correctly? (continues on the next page) 5-4 MAPRME05 - Rev.0

109 5.1 Receiving unit diagnostic Is the ENABLE light lit? Look radio module diagnostic ( 5.3) CALL SERVICE Does the system start correctly? Replace the address key. Does the system start correctly? Disconnect the power from the receiving unit. Is the F2 fuse integral? Replace F2 ( 5.8) o ( 5.9) Is the F3 fuse integral? Has the internal wiring of the receiving unit been carried out correctly? Carry out the correct wiring (see technical data sheet) Replace F3 ( 5.8) o ( 5.9) Replace analogue module diagnostic ( 5.5) Does the system start correctly? Sostituire la scheda relè presente nello slot 4. ( 5.6) Does it start? Replace master board ( 5.8) o ( 5.9) Does the system start correctly? CALL SERVICE MAPRME05 - Rev.0 5-5

110 5.2 Exploded view and spare parts 5.2 Exploded view and spare parts Exploded view Spare parts 5-6 N Code Description 5.14 F0ANTE00E17A0 External antenna at 433 MHz 5.13 F0ANTE00E30A0 Internal antenna at 870 MHz 5.8 F0BASE00E39A0 24 Vdc master board (SBR97DC01) 5.8 F0BASE00E39B0 24 Vdc master board for external antenna (SBR97DC03) 5.8 F0BASE00E39C0 24 Vdc master board for cable control (SBR97DC05) 5.9 F0BASE00E40A0 ac master board (SBR97AC01) 5.9 F0BASE00E40C0 ac master board for external antenna (SBR97AC02) 5.8 F0BASE00E46A0 12 Vdc master board (SBR97DC01) 5.8 F0BASE00E46B0 12 Vdc master board for external antenna (SBR97DC03) 5.8 F0BASE00E46C0 12 Vdc master board for cable control (SBR97DC05) 5.15 F0CAVI00E89A0 Internal extension cable for antenna (40 cm) MAPRME05 - Rev.0

111 5.2 Exploded view and spare parts 5.16 F0CAVI01E18A0 Cable for wiring with recovery diodes 5.10 F0ESBA01E02A0 24V power supply card (SBA97V24D02A) 5.10 F0ESBA01E06A0 24V power supply card (SBA97V12-24L) 5.10 F0ESBA01E06B0 12V power supply card (SBA97V12-24K) 5.4 F0RIDE00E10A0 RD97-00A receiver decoder module 5.4 F0RIDE00E10B0 RD97-00B receiver decoder module with SAFETY progr. 5.3 F0RIRA00E11A0 MRXEU03A radio receiver module (frequency 433 MHz) 5.3 F0RIRA00E11B0 MRXAU03A radio receiver module (frequency 472 MHz) 5.3 F0RIRA00E11D0 MRXUK03A radio receiver module (frequency 458 MHz) 5.3 F0RIRA00E14A0 MRXEU06B radio receiver module (frequency 870 MHz) 5.14 F0SCIN00E50A0 Support for external antenna 5.6 F0ESBA00E03A0 24V 7 relay card (SR97R07S1LA) 5.6 F0ESBA00E05A0 24V 7 relay card with double contact SR97R07S2LA 5.6 F0ESBA00E07A0 12V 7 relay card (SR97R07S1KA) 5.6 F0ESBA00E08A0 12V 7 relay card with double contact (SR97R07S2KA) 5.6 F0ESBA00E11A0 24V 7 relay card (SR97IR7S1LA) for IR system 5.6 F0ESBA00E13A0 24V 9 relay card with 2 relays for SAFETY (SR97R09S1LA) 5.6 F0ESBA00E14A0 24V 7 relay card for up/down analogue commands (SR97R07V1LA) 5.6 F0ESBA00E15A0 24V 7 relay card for BCD analogue commands (SR97R07V4LA) 5.6 F0ESBA00E16A0 24V 7 relay card with double contact with FLOW (SR97R07S2LB) 5.6 F0ESBA00E17A0 24V 8 relay card with a configurable relay (SR97R08S1LA) 5.6 F0ESBA00E18A0 24V 8 relay card with a configurable relay (SR97R08S1KA) 5.6 F0ESBA00E19A0 24V 5 relay configurable card (SR97R05S1LA) 5.6 F0ESBA00E20A0 14V 5 relay configurable card (SR97R05S1KA) 5.6 F0ESBA00E29A0 24V 7 relay card for BCD/PWM analogue comm. (SR97R07P4LA) 5.15 G0ANTE00E10A0 433 MHz external antenna with 5 metre cable 5.15 G0ANTE00E27A0 433 MHz external antenna with 10 metre cable 5.15 G0ANTE00E28A0 433 MHz external antenna with 1 metre cable 5.15 G0ANTE00E31A0 870 MHz external antenna with 5 metre cable 5.7 G0INRI00E39A0 24V 3 relay TS, ENA, F1 (RI97R03S1LA) 5.7 G0INRI00E39B0 24V 3 relay ENA, ENA, F1 (RI97R03S1LB) 5.7 G0INRI00E40A0 12V 3 relay TS, ENA, F1 (RI97R03S1KA) 5.7 G0INRI00E40B0 12V 3 relay ENA, ENA, F1 (RI97R03S1KB) 5.5 G0INRI00E45A0 RI97-08V0ZA analogue receiver module with voltage outputs 5.5 G0INRI00E46A0 RI97-08P0ZA analogue receiver module with PWM outputs 5.12 R0CASS00P03A0 Receiving case with 24/64 pole plug 5.12 R0CASS00P04A0 Receiving case with cable entry 5.12 R0CASS00P05A0 Receiving case with 32 pole (reduced) plug 5.12 R0CASS00P06A0 Receiving case with 40 pole plug 5.12 R0CASS00P18A0 Receiving case with 32 pole pug with cover "N " is the paragraph number which refers to the spare part. Warning No voltage should be present when carrying out any internal operations (replacement or programming) on the receiving unit, therefore make sure that the power is disconnected from the receiving unit before proceeding. MAPRME05 - Rev.0 5-7

112 5.3 Radio receiver module (MRX 0 ) 5.3 Radio receiver module (MRX 0 ) Codici MRXEU03A MRXUK03A MRXEU06B MRXAU03A Radio receiver module frequency 433 MHz Radio receiver module frequency 458 MHz (module for England) Radio receiver module frequency 870 MHz Radio receiver module frequency 472 MHz (module for Australia) Always make sure that the frequencies at which the radio receiving module operates are permitted in the country where the radio remote control is to be used. Module components Led 1 (green colour) Led 2 (green colour) Led 3 (green colour) Dip switches Master board connettor Antenna cable connector Leds The three LEDs that are present indicate if the radio receiving module: - is being supplied correctly (LED 1) - is receiving a radio signal at the operating frequency (LED 2) - is scanning the frequencies (when LED 3 blinks) Dip switches The eight dip switches present in the radio receiving module define the frequency operation mode (automatic scan or manual selection) and the operating frequency itself: : MHz (sempre OFF) MHz MHz Frequency value for each MHz DIP in the ON position MHz MHz MHz ON = manuale selection OFF = automatic scan The radio receiving module dip switches must always be set in the same manner as the dip switches of the radio transmitter encoder module. 5-8 MAPRME05 - Rev.0

113 5.3 Radio receiver module (MRX 0 ) Diagnostic Is LED 1 lit? Replace the radio receiver module. Does the system start? Is the light of LED 2 steady and is the transmitting unit switched off? Carry out the frequency change procedure. Does the system start? Replace the radio receiver module and the radio transmitter encoder module. Se il sistema non si avvia, CHIAMARE ASSISTENZA Is the LED 2 light steady and the transmitting unit powered? Is the LED 3 light steady? Replace the radio receiving module. Does the system start? Is the LED 3 light blinking and is DIP 8 at the OFF position? Carry out the frequency change procedure. Does the system start? Check the receiver decoder module diagnostic ( 5.4) Check the connections of the external antenna (if present). Does the system start? Replace the radio receiving module and the radio transmitter encoder module If the system does not start, CALL SERVICE MAPRME05 - Rev.0 5-9

114 5.3 Radio receiver module (MRX 0 ) Replacement Disassembly Assembly 1. Open the receiving unit by rotating the plastic key in a clockwise direction. 6. Close the receiving unit by turning the plastic key in an anti-clockwise direction. 2. Release the module, pressing the metal discs on the two electronic card guides on the second slot from the left. 5. Lock the module by pressing the two black pins on the card guides. 3. Extract the radio receiver module. 4. After having set the dip switches, insert the new radio receiver module into the two card guides MAPRME05 - Rev.0

115 5.3 Radio receiver module (MRX 0 ) Automatic scan mode For this type of mode it is necessary to: 1) set DIP8 at OFF 2) select the requested frequency group by setting the eight dip switches for each module as explained in the following tables: MTXEU03A Group 1 Group 2 Group 3 Group 4 Position DIP 2, 3 e 4 OFF, OFF, OFF ON, OFF, OFF OFF, ON, OFF ON, ON, OFF Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Group 5 Group 6 Group 7 Group 8 Position DIP 2, 3 e 4 OFF, OFF, ON ON, OFF, ON OFF, ON, ON ON, ON, ON Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz Freq MHz MHz MHz MHz In this module, DIPs 5, 6 and 7 do not effect the setting of the frequency group while DIP 1 must be set to OFF. The available frequencies are those belonging to the set group MAPRME05 - Rev

116 5.3 Radio receiver module (MRX 0 ) MTXUK03A In this module, the DIPs from 2 to 7 are inactive and do not influence in the choice of the frequency group, while DIP 1 must be set at OFF. MTXEU06B In this module, the DIPs from 2 to 7 are inactive and do not influence in the choice of the frequency group, while DIP 1 must be set at ON. MTXAU03A In this module the DIPs from 2 to 7 must be set in order to operate within the permitted frequencies:. DIP 1 DIP 2 DIP 3 DIP 4 DIP 5 DIP 6 DIP 7 DIP 8 OFF ON OFF OFF ON OFF ON OFF 5-12 MAPRME05 - Rev.0

117 5.3 Radio receiver module (MRX 0 ) Manual frequency mode For this type of mode it is necessary to: 1) set DIP8 at ON 2) select the frequency by setting the DIPs from 2 to 7 as explained below as a function of the radio transmitter encoder module: MRXEU03A MAPRME05 - Rev

118 5.3 Radio receiver module (MRX 0 ) MRXUK03A The DIPs that are present make it possible to set other frequencies (see Dip switches page 8) which are not, however, permitted. MRXEU06B The DIPs that are present make it possible to set other frequencies (see Dip switches page 8) which are not, however, permitted. MRXAU03A The DIPs that are present make it possible to set other frequencies (see Dip switches page 8) which are not, however, permitted MAPRME05 - Rev.0

119 5.4 Receiver decoder module (RD97-00A) 5.4 Receiver decoder module (RD97-00A) Module components Led 2 (green colour) Led 3 (green colour) Led 4 (red colour) Led 1 (green colour) Connettore per la chiave di codice Master board connector Diagnostic Is LED 4 lit? Is the power supply voltage of the receiving unit correct? Correctly power the receiving unit. Does the system start? Return to the receiving unit diagnostic. ( 5.1) Replace the receiver decoder module. Does the system start? Replace the master board ( 5.8) or ( 5.9) Does the system start? Return to the receiving unit diagnostic. ( 5.1) Leds MAPRME05 - Rev.0 The four LEDs present on the receiver decoder module indicate: LED 1 (green) ON : module being powered correctly with a steady voltage of between 9 and 15 Vdc OFF: module being powered incorrectly LEDs 2 and 3 (green) ON: module operating correctly 5-15

120 5.4 Receiver decoder module (RD97-00A) Replacement OFF: module not operating correctly These two LEDs must blink during the test phase after power on and before true operation. LED 4 (red) ON: the module is signalling the presence of a fault in the system OFF: the module is operating correctly Disassembly Assembly 1. Open the receiving unit by rotating the plastic key in a clockwise direction. 8. Close the receiving unit by turning the plastic key in an anti-clockwise direction. 2. Release the module, pressing the metal discs on the two electronic card guides on the first slot from the left. 7. Lock the module by pressing the two black pins on the card guides. 3. Extract the receiver decoder module. 6. Insert the new receiver decoder module into the two card guides. 4. Extract the address key from the receiver decoder module. 5. Insert the address key in the new receiver decoder module MAPRME05 - Rev.0

121 5.5 Analogue receiver module (RI97-08_0ZA) 5.5 Analogue receiver module (RI97-08_0ZA) Codes RI97-08V0ZA RI97-08P0ZA Analogue receiver module with voltage outputs Analogue receiver module with PWM outputs Module components Connector for the auxiliary proportional output Rotary Green led Connector for the proportional outputs Reset pushbutton Connettore per l alimentazione Data memory Connector for the calibration key Master board connector Calibration key Information about module 1) Never leave the K1 calibration key inserted during radio remote control use. The key is only needed during the calibration phase and, when inserted, only one proportional command can be activated at a time. 2) The proportional outputs of RI97-08 module are programmed at the values given on the relevant technical data sheet. 3) To keep the same settings in case of module replacement, move the K2 memory from the old module to the new one. Welding points Some welding points are present on the analogue receiver module: PAD STATE DESCRIPTION S3 stabilised voltage S3 in step voltage S4 RI97-08P0ZA configuration S4 RI97-08V0ZA configuration S3 is the right-hand welding point, S4 the left one The S4 welding point must be closed in RI97-08P0ZA modules, while it must be open in the RI97-08V0ZA module. To set S3 please keep in mind the following: Stabilised voltage: the voltage of the module outputs are always related to an absolute voltage value. In step voltage: the module output voltages are related to the true power supply values. MAPRME05 - Rev

122 5.5 Analogue receiver module (RI97-08_0ZA) PAD STATE DESCRIPTION S1 RI97-08V0ZA configuration S1 RI97-08P0ZA configuration The S1 setting can at times be different from what is indicated above. Check the current setting given in the technical data sheet, and during replacement verify that the new module is set in the same manner as the one to be replaced. Replacement Disassembly Assembly 1. Open the receiving unit by rotating the plastic key in a clockwise direction. 6. Close the receiving unit by turning the plastic key in an anti-clockwise direction. 2. Release the module, pressing the metal discs on the two electronic card guides on the third slot from the left. 5. Lock the module by pressing the two black pins on the card guides. 3. Remove the wiring connectors from the analogue receiver module. Extract the module. 4. Insert the new analogue receiver module into the two card guides. Insert the wiring into the respective connectors MAPRME05 - Rev.0

123 5.5 Analogue receiver module (RI97-08_0ZA) Preparation for setting Rotary switch setting 1. Make sure that the transmitting unit is switched off. 2. Disconnect the power from the receiving unit. 3. Open the receiving unit and insert the K1 settings key into the C4 connector. 4. Power the receiving unit. ATTENTION: From this moment onwards do not touch the receiving unit until setting up has been completed (otherwise you risk losing the settings that have already been set) 5. Turn the transmitting unit ignition key to "I" and press the START pushbutton. 6. Turn the starting key to the position (REMOTE SET UP). 7. Select the parameters to be set using the rotary switch S, which can be found on the RI97-08 module, and the RPM+/- selector, which is present on the transmitting unit (+ increases the value being set, - decreases it). Setting modules with voltage outputs In modules with voltaged outputs it is possible to set positions 1, 2, 3, 4 and 5. In modules with current outputs (PWM) it is possible to set positions 0, 1, 3 and 4. When the rotary switch S is at 1 POSITION, it is possible to regulate the maximum and minimum voltage values of the two semiaxes of a joystick. Proceed as follows: 1. To set the maximum value, take the joystick to the maximum range of the semiaxis to be calibrated. Use the toggle switch RPM +/- to modify the value while maintaining same joystick position. 2. To set the minimum value, take the joystick just out of the rest position of the semiaxis to be calibrated. Use the toggle switch RPM +/- to modify the value while maintaining same joystick position. When the rotary switch S is at 2 POSITION, it is possible to regulate the voltage value which corresponds to the mechanical rest position of the joystick. Normally, this value shouldn t be modified. Proceed as follows: - take any joystick out of the rest position - use the toggle switch RPM +/- to modify the value while maintaining same joystick position. When the rotary switch S is at 3 and 4 POSITION, it is possible to regulate the maximum and minimum voltage values of auxiliary outputs Z8 and Z9 respectively. Proceed as follows: 1. To set the maximum value, turn the Z8 (or Z9) command knob (present in the transmitting unit) fully clockwise. Use the toggle switch RPM +/- to modify the value while maintaining same knob position. 2. To set the minimum value, turn the Z8 (or Z9) command knob (present in the transmitting unit) fully counterclockwise. Use the toggle switch RPM +/- to modify the value while maintaining same knob position. Semiaxis direction is inverted when the rotary switch S is at 5 POSITION. Proceed as follows: - take the joystick of the axis to be inverted out of the rest position - while maintaining this situation, use the toggle switch RPM +/- on the transmitting unit. Move it to + in order to invert the semiaxis direction or to - in order to reset the semiaxis direction. MAPRME05 - Rev

124 5.5 Analogue receiver module (RI97-08_0ZA) Setting modules with PWM outputs When the rotary switch S is at 0 POSITION, the PWM (current) signal frequency can be adjusted. Normally this value shouldn t be modified. If necessary, proceed as follows: - take one joystick out of the rest position - use the toggle switch RPM +/- to modify the value while maintaining same joystick position. When the rotary switch S is at 1 POSITION, it is possible to regulate the maximum and minimum voltage (or current) values of the two semiaxes of a joystick. Proceed as follows: 1. To set the maximum value, take the joystick to the maximum range of the semiaxis to be calibrated. Use the toggle switch RPM +/- to modify the value while maintaining same joystick position. 2. To set the minimum value, take the joystick just out of the rest position of the semiaxis to be calibrated. Use the toggle switch RPM +/- to modify the value while maintaining same joystick position. When the rotary switch S is at 3 and 4 POSITION, it is possible to regulate the maximum and minimum voltage values of auxiliary outputs Z8 and Z9 respectively. Proceed as follows: 1. To set the maximum value, turn the Z8 (or Z9) command knob (present in the transmitting unit) fully clockwise. Use the toggle switch RPM +/- to modify the value while maintaining same knob position. 2. To set the minimum value, turn the Z8 (or Z9) command knob (present in the transmitting unit) fully counterclockwise. Use the toggle switch RPM +/- to modify the value while maintaining same knob position. Saving the settings Important notes about setting 8. Switch off the transmitting unit to save the settings. 9. Disconnect power from the receiving unit. 10. Extract the K1 settings key. 11. Close the receiving unit and power it. If the joystick is moved out of its rest position during setting, the horn/alarm sounds for 0.5 seconds, indicating that you are in the minimum setting area. Each single position of the speed selector present on the transmitting unit must be set. Output values reset To reset the initial proportional output values (i.e. those given in the technical data sheet), with calibration key K1 inserted, just keep reset button P pressed until the green led L stops flashing and remains lit MAPRME05 - Rev.0

125 5.6 Relay card (SR97R0 ) 5.6 Relay card (SR97R0 ) Codes Card components SR97R07S1LA SR97R07S2LA SR97R07S1KA SR97R07S2LA SR97R07S2LB SR97IR7S1LA SR97R09S1LA SR97R07V1LA SR97R07V4LA SR97R07P4LA SR97R08S1LA SR97R08S1KA SR97R05S1LA SR97R05S1KA 24V 7 relay card 24V 7 relay card with double contact for each relay 12V 7 relay card 12V 7 relay card with double contact for each relay 24V 7 relay card with double contact for each relay and with FLOW 24V 7 relay card for IR system 24V 9 relay card with 2 relays for SAFETY 24V 7 relay card for up/down analogue commands 24V 7 relay card for BCD analogue commands 24V 7 relay card for BCD/PWM analogue commands 24V 8 relay card with a configurable relay 12V 8 relay card with a configurable relay 24V 5 relay configurable card 12V 5 relay configurable card Relay contact terminals (for wiring) Relay Master board connector The capacity of the relay contacts is: 10 A, 250 V. MAPRME05 - Rev

126 5.6 Relay card (SR97R0 ) Replacement Disassembly Assembly 1. Open the receiving unit by rotating the plastic key in a clockwise direction. 6. Close the receiving unit by turning the plastic key in an anti-clockwise direction. 5. Lock the card by pressing the two black pins on the card guides. 3. Remove the wiring connectors from the relay card. Extract the card. 2. Release the card by pressing the metal discs on the two card guides of the slot that hold the relay card that is to be replaced. 4. Insert the new relay card into the two card guides. Insert the wiring into the respective connectors. Additional information SR97R07S A The relay cards with double contact make it possible for a single command to act on two electrically separate parts. SR97R07S2LB This relay card can only be inserted into slot 4 of DC master boards. This differs from the SR97R07S2LA because the FLOW command is not delayed at deactivation MAPRME05 - Rev.0

127 5.6 Relay card (SR97R0 ) SR97R07V1LA This card generates a voltaged analogue output, the value of which is increased (UP) or decreased (DOWN) by a selector on the transmitting unit. The commands that carry out the UP and DOWN function are configured by programming the matrix of pads using wire bridges. It is also possible to set using trimmers: - the initial and final value of the analogue output to be varied, - the increment/decrement time of the output voltage. Connect the "G" pad with the "G_" pad to carry out the UP function, and the "F" pad with the "F_" pad to carry out the DOWN function. configurable matrix Output voltage Vout < 0,9 POWER SUPPLY Minimum adjustable voltage Vbasic = 0 0,9 POWER SUPPLY Maximum adjustable voltage Vmax = 0 0,9 POWER SUPPLY GND: 0V of the analogue signal RV: analogue signal output increment/decrement time of the output voltage: adjustable from between 5 and 15 seconds MAPRME05 - Rev

128 5.6 Relay card (SR97R0 ) SR97R07_4LA This card generates a voltage analogue output, the value of which depends on the position of a BCD selector placed inside the transmitting unit. The commands that set the level of this analogue output are configured by programming the matrix of pads by way of wire bridges. It is also possible to set the initial and final value of the analogue output to be varied using trimmers. Configure the matrix pads in the same manner as the relay card that is to be replaced. configurable matrix Output voltage Vout < 0,9 POWER SUPPLY Minimum adjustable voltage Vbasic = 0 0,9 POWER SUPPLY Maximum adjustable voltage Vmax = 0 0,9 POWER SUPPLY GND: 0V of the analogue signal RV: analogue signal output 5-24 MAPRME05 - Rev.0

129 5.6 Relay card (SR97R0 ) SR97R08S1_A The eighth relay present on the card is used to have a same command available at two different outputs of the receiving unit. This relay can be configured programming the matrix of pads by way of wire bridges. Connect pad "C" with pad "F_" or "G_" according to which signal is to be doubled. configurable matrix SR97R09S1LA The two additional relays (the characteristics of which are 5A, 250V) can be configured by programming the matrix of pads by way of wire bridges. They are used to obtain 2 additional SAFETYs. Connect pads "C1" and "C2" to pads "S1" and "S2" to activate 2 additional SAFETYs. The fuse present on the card has the following characteristics: (5x20) mm, 5A, 250 V. configurable matrix MAPRME05 - Rev

130 5.6 Relay card (SR97R0 ) SR97R05S1_A The SR97R05S1_A card holds 5 programmable relays: - three relays can either save a Set/Reset command of F/G pair commands or carry out the function of auxiliary relays (therefore directly controlled by an external power supply source at 24 and 12 Vdc) - two relays can be programmed with the START/F1, TIMED STOP or ENABLE functions. NOTE: The Set/Reset command is forgotten if stops or passive emergencies occur. second group of 3 relay first group of 3 relay FIRST GROUP OF 3 RELAYS (RL1 RL3) To programme the SET function, connect one of the F2 F7 pads to S1 3 (activation of the command programmed at pad S1 3 causes closure of the relative RL1 RL3 relay) To programme the RESET function, connect one of the G2 G7 pads to R1 3 (activation of the command programmed at pad R1 3 causes opening of the relative RL1 RL3) N.B.: if Fn is programmed with S1 3 connect Gn to R1 3 To programme the relays as auxiliary relays, connect one or more IN1 3 terminals to S1 3 and contemporaneously cut the corresponding resistor (R6 if S1 is programmed, R7 if S2 is programmed and R8 if S3 is programmed). SECOND GROUP OF 2 RELAYS (RL4 and RL5) Connect pads 4 and 5 (respectively for RL4 and RL5) with the ENA pad (to programme the ENABLE signal). Connect pads 4 and 5 (respectively for RL4 and RL5) to the ENA pad (to programme the ENABLE signal), TS (to programme the TIMES STOP signal) and F1 (to programme the F1/ALARM signal) MAPRME05 - Rev.0

131 5.7 3 relay card (RI97R03S1 ) relay card (RI97R03S1 ) Codes Card components RI97R03S1LA RI97R03S1LB RI97R03S1KA RI97R03S1KB 24V 3 relay card for TIMED STOP, ENABLE e F1 24V 3 relay card for ENABLE, ENABLE e F1 12V 3 relay card for TIMED STOP, ENABLE e F1 12V 3 relay card for ENABLE, ENABLE e F1 Relay Relay contact terminals (for wiring) Replacement Master board connector Disassembly Assembly 1. Open the receiving unit by rotating the plastic key in a clockwise direction. 2. Release the card by pressing the metal discs on the card guides in the slot on the bottom right (number 9). 5. Lock the relay card by pressing the two black pins on the card guides. 3. Separate the wiring connectors from the relay card. Extract the card. 6. Close the receiving unit by turning the plastic key in an anti-clockwise direction. 4. Insert the new relay card into the two card guides. Insert the wiring into the respective connectors. MAPRME05 - Rev

132 5.8 DC master board (SBR97DC ) 5.8 DC master board (SBR97DC ) Codes Board components SBR97DC01 SBR97DC02 SBR97DC03 SBR97DC04 SBR97DC05 SBR97DC06 24 Vdc master board 12 Vdc master board 24 Vdc master board for external antenna 24 Vdc master board operating 870 MHz Master board for radio remote control operating at 870 MHz 12 Vdc master board for external antenna Master board for radio remote control operating at 870 MHz 24 Vdc master board for cable control 12 Vdc master board for cable control Antenna Dip switches Connectors Weldings points Welding points Fuses Power supply connector Module and card layout As shown in the example, it is always necessary to insert: - the RD97 receiver decoder module into slot 1; - the MRX radio receiver module into slot 2; - the RI 97 analogue receiver module into slot 3; - an SR97 relay card into slots 4, 5, 6, 7; - the 24Vdc or 12Vdc power supply card into slot 8; - a possible optional module into slot MAPRME05 - Rev.0

133 5.8 DC master board (SBR97DC ) Diagnostic Replace the power supply card. ( 5.10) Does the system start correctly? Replace the master board. Does the system start correctly? CALL SERVICE MAPRME05 - Rev

134 5.8 DC master board (SBR97DC ) Replacement Disassembly Assembly 1. Open the receiving unit by rotating the plastic key in a clockwise direction. 6. Close the receiving unit by turning the plastic key in an anti-clockwise direction. 2. Extract all the modules and the cards (with respective wiring) that are present inside the receiving unit. 5. Insert the modules and the cards (with their respective wiring) into the relative slots. 3. Extract the master board by unscrewing the four nuts that are present (disconnect the external antenna if present). 4. (Connect the external antenna if present) Insert the new master board and tighten the four nuts MAPRME05 - Rev.0

135 5.8 DC master board (SBR97DC ) Connectors The signals in the pins of the connectors present in the master board are laid out as follows: (RESERVED: pin for a control signal) Connector for electrical connection with the receiver modules (slots 1, 2 and 3) Connectors for electrical connection with the relay cards (slot 4, 5, 6 and 7) Connectors for electrical connection with the 3-relay cards (slot 9) The pins indicated by SETUP relative to slots 4, 5, 6 and 7 have different signals, according to the slot: MAPRME05 - Rev.0 PIN SLOT 4 SLOT 5 SLOT 6 SLOT 7 18 F2 G2 F8 G8 19 F3 G3 F9 G9 20 F4 G4 F10 G10 21 F5 G5 F11 G11 51 FLOW F1 F1 TS 52 F6 G6 F12 G12 53 F7 G7 F13 G

136 5.8 DC master board (SBR97DC ) Power supply Carry out power supply wiring in the following manner: - connect the power supply neutral to the 0V terminal; - connect the positive to the +12 or +24 Vdc terminal, in accordance with the voltage value. The "OUT 12/24 Vdc" terminal supplies the POWER and ENABLE signalling lights. Wire the STOP and SAFETY relays as indicated in the technical data sheet of the radio remote control. Fuses Name Function Caracteristics F1 F2 F3 POWER SUPPLY circuit protection STOP circuit protection SAFETY circuit protection 2A (for 24Vdc) and 4A (for 12 Vdc) (5x20mm; 250V) 10A (5x20mm; 250V) 10A (5x20mm; 250V) 5-32 MAPRME05 - Rev.0

137 5.8 DC master board (SBR97DC ) Welding points and dip switches DSW1 POSITION DESCRIPTION 1 ON F7 activated by G7 2 ON F6 activated by G6 3 ON F5 activated by G5 4 ON F4 activated by G4 5 ON F3 activated by G3 6 ON F2 activated by G2 DSW2 POSITION DESCRIPTION 1 ON F13 activated by G13 2 ON F12 activated by G12 3 ON F11 activated by G11 4 ON F10 activated by G10 5 ON F9 activated by G9 6 ON F8 activated by G8 When the dip switches are OFF, the different settings are deactivated ( (F_ not activated by G_) PAD STATE DESCRIPTION S1 SAFETY activated by F2 G7 S1 SAFETY activated by F1 G13 S2 Passive emercency time = 1.5 s S2 Passive emercency time = 0.5 s S3 F2 (or F3) held by G2 (or G3) S3 disabled function S4 F4 (or F5) held by G4 (or G5) S4 disabled function MAPRME05 - Rev

138 5.9 AC master board (SBR97AC ) 5.9 AC master board (SBR97AC ) Codes Board components SBR97AC01 SBR97AC02 ac master board ac master board for external antenna Master board for radio remote control operating at 870 MHz Antenna Dip switches Connectors Welding points Fuses Fuses Trasformer Power supply connector Module and card layout As shown in the example, it is always necessary to insert: - the RD97 receiver decoder module into slot 1; - the MRX radio receiver module into slot 2; - the RI 97 analogue receiver module into slot 3; - an SR97 relay card into slots 4, 5, 6, MAPRME05 - Rev.0

139 5.9 AC master board (SBR97AC ) Diagnostic Disconnect the powerfrom the receiving unit. Is the F4 fuse integral? Replace F5. Dose the system start correctly? Is the F5 fuse integral? Replace F5. Dose the system start correctly? Replace the master board. Does the system start correctly? CALL SERVICE MAPRME05 - Rev

140 5.9 AC master board (SBR97AC ) Replacement Disassembly Assembly 1. Open the receiving unit by rotating the plastic key in a clockwise direction. 6. Close the receiving unit by turning the plastic key in an anti-clockwise direction. 2. Extract all the modules and the cards (with respective wiring) that are present inside the receiving unit. 5. Insert the modules and the cards (with their respective wiring) into the relative slots. 3. Extract the master board by unscrewing the four nuts that are present (disconnect the external antenna if present). 4. (Connect the external antenna if present) Insert the new master board and tighten the four nuts MAPRME05 - Rev.0

141 5.9 AC master board (SBR97AC ) Connectors The signals in the pins of the connectors present in the master board are laid out as follows: (RESERVED: pin for a control signal) Connector for electrical connection with the receiver modules (slots 1, 2 and 3) Connectors for electrical connection with the relay cards (slot 4, 5, 6 and 7) The pins indicated by SETUP relative to slots 4, 5, 6 and 7 have different signals, according to the slot: PIN SLOT 4 SLOT 5 SLOT 6 SLOT 7 18 F2 G2 F8 G8 19 F3 G3 F9 G9 20 F4 G4 F10 G10 21 F5 G5 F11 G11 51 ENABLE F1 F1 TS 52 F6 G6 F12 G12 53 F7 G7 F13 G13 MAPRME05 - Rev

142 5.9 AC master board (SBR97AC ) Power supply Carry out power supply wiring as follows: - connect the neutral to terminal N; - connect the phase to the Vac terminal in accordance with the voltage value. The "OUT 12/24 Vdc" terminal supplies the POWER and ENABLE signalling lights. ATTENTION: all POWER SUPPLY terminals have voltage. Don t touch them if the receiving unit is powered. Wire the STOP and SAFETY relays as indicated in the technical data sheet of the radio remote control. Fuses Name Function Caracteristics F1 POWER SUPPLY circuit protection 2A (5x20mm; 250V) F2 F3 F4 F5 STOP circuit protection SAFETY circuit protection transformer secondary circuit protection transformer primary circuit protection 10A (5x20mm; 250V) 10A (5x20mm; 250V) 0.5A (5x20mm; 250V) 2A (5x20mm; 250V) 5-38 MAPRME05 - Rev.0

143 5.9 AC master board (SBR97AC ) Welding points and dip switches DSW1 POSITION DESCRIPTION 1 ON F7 activated by G7 2 ON F6 activated by G6 3 ON F5 activated by G5 4 ON F4 activated by G4 5 ON F3 activated by G3 6 ON F2 activated by G2 DSW2 POSITION DESCRIPTION 1 ON F13 activated by G13 2 ON F12 activated by G12 3 ON F11 activated by G11 4 ON F10 activated by G10 5 ON F9 activated by G9 6 ON F8 activated by G8 When the dip switches are OFF, the different settings are deactivated ( (F_ not activated by G_) PAD STATE DESCRIPTION S1 SAFETY activated by F2 G7 S1 SAFETY activated by F1 G13 S2 Passive emercency time = 1.5 s S2 Passive emercency time = 0.5 s S3 F2 (or F3) held by G2 (or G3) S3 disabled function S4 F4 (or F5) held by G4 (or G5) S4 disabled function MAPRME05 - Rev

144 5.10 Power supply card (SBA97V ) 5.10 Power supply card (SBA97V ) Codes Card component SBA97V24D02A SBA97V12-24L SBA97V12-24K 24V power supply card 24V power supply card 12V power supply card The SBA97V24D02A power supply card must only be inserted into slot 8 of the 24Vdc master boards. SBA97V24D02A SBA97V12-24L SBA97V12-24K The SBA97V12-24L power supply card must only be inserted into slot 8 of the 24Vdc master boards. The SBA97V12-24k power supply card must only be inserted into slot 8 of the 12Vdc master boards. The SBA97V12-24L e SBA97V12-24K power supply contain a fuse having the following characteristics: 5x20 mm; 5A; 250V MAPRME05 - Rev.0

145 5.10 Power supply card (SBA97V ) Replacement Disassembly Assembly 1. Aprire l unità ricevente ruotando in senso orario la chiave di plastica. 6. Close the receiving unit by turning the plastic key in an anti-clockwise direction. 2. Release the card by pressing the metal discs positioned on the two card guides of the slot in the lower centre (number 8). 5. Lock the card by pressing the two black pins on the card guides. 3. Extract the power supply card. 4. Insert the new power supply card into the two card guides. MAPRME05 - Rev

146 5.11 Address keys 5.11 Address keys Description The receiver decoder module is equipped with an address key that contains the address of the radio remote control. This key is: - coloured grey - removable - necessary for radio remote control operation - unique, like the serial number given on the label. WARNING! The radio encoder trasmitter module contains the corresponding address key, which has the same address (and serial number given on the label). This key is, however, coloured yellow. DO NOT INTERCHANGE THE TWO AD- DRESS KEYS (the radio remote control would not operate) MAPRME05 - Rev.0

147 5.12 Receiving case 5.12 Receiving case Codes Case components R0CASS00P03A0 R0CASS00P04A0 R0CASS00P05A0 R0CASS00P06A0 R0CASS00P18A0 Receiving case with 24/64 poles plug Receiving case with pressacavo Receiving case with spina 32 poles (reduced) plug Receiving case with spina 40 poles plug Receiving case with 32 poles plug with cover Identification plate Technical data plate POWER light ENABLE light Plastic open/close key Multiple plug (or cable entry) Internal wiring for the POWER and ENABLE lights Lights The POWER and ENABLE lights signal: POWER: the presence of power supply in the receiving unit ENABLE: radio link between the transmitting and receiving units When the receiving unit is powered, operation is correct if: - POWER and ENABLE are lit when the transmitting unit is started - POWER is lit and ENABLE switched off when the transmitting unit is switched off. MAPRME05 - Rev

148 5.12 Receiving case Replacement Disassembly Assembly 1. Aprire l unità ricevente ruotando in senso orario la chiave di plastica. 6. Close the receiving unit by turning the plastic key in an anti-clockwise direction. 2. Separate the wiring connectors from all the electronic cards present inside the receiving unit. 5. Carry out wiring of the receiving unit (see radio remote control technical data sheet). 3. Extract the master board (with the modules and the electronic cards in their seats) by unscrewing the four nuts that are present. 4. Insert the master board (with the modules and the electronic cards in their seats) and tighten the four relative nuts MAPRME05 - Rev.0

149 5.13 Internal antenna at 870 MHz 5.13 Internal antenna at 870 MHz Antenna components Connector SMB Antenna cable Adhesive strips This antenna must use the F0BASE00E B0 master boards. Replacement Disassembly Assembly 1. Extract the master board (see ( 5.8) or ( 5.9)) 6. Insert the master board (see ( 5.8) or ( 5.9)) 2. Separate the SMB connector of the antenna from the SMB2 connector, printed on the soldering side of the master board. 5. Insert the SMB connector of the antenna into the SMB2 connector, printed on the soldering side of the master board. 3. Extract the antenna from the upper part of the receiving case. 4. Remove the adhesive straps from the antenna and attach it to the upper part of the receiving case. MAPRME05 - Rev

150 5.14 External antenna with support 5.14 External antenna with support Antenna components Connector SMB Adhesive strips Antenna Antenna cable Connector for antenna Antenna support This antenna must use the F0BASE00E B0 master boards. Replacement Disassembly Assembly 1. Extraxt master board (see ( 5.8) or ( 5.9)) and unscrew the antenna. 6. Insert master board (see ( 5.8) or ( 5.9)) and screw in the antenna. 2. Separate the SMB connector of the antenna from the SMB2 connector, printed on the soldering side of the master board. 5. Insert the SMB connector of the antenna into the SMB2 connector, printed on the soldering side of the master board. 3. Unscrew the fixing nut present externally on the receiving case (on the antenna connector). Extract the antenna support from the receiving case. 4. Remove the adhesive straps from the support and attach it inside the receiving case. Tighten the nut on the antenna connector MAPRME05 - Rev.0

151 5.15 External antenna with cable 5.15 External antenna with cable Codes G0ANTE00E10A0 G0ANTE00E27A0 G0ANTE00E28A0 G0ANTE00E31A0 433 MHz external antenna with 5 metres cable 433 MHz external antenna with 10 metres cable 433 MHz external antenna with 1 metre cable 870 MHz external antenna with 5 metres cable Indications If the receiving unit is covered by metallic structures or installed inside electric panels, use the external antenna option with a cable of 1, 5 or 10 metres according to need. Install it in a position that favours reception of the signals emitted by the transmitting unit. Preparing the receiving case The antenna must always be assembled on the supplied bracket or on a metallic support plate, but the antenna stylus must never come into contact with metallic parts. These antennas must use F0BASE00E B0 master boards. Before assembling an external antenna it is necessary to do the following: 1) drill the bottom of the receiving case (the part with the plug or the cable entry). The position of the hole must be identical to that indicated in the figure (measurements in mm): 2) use the F0CAVI00E89A0 cable for internal connection. The end with the BNC connector should be positioned into the hole that has been made (see figure) while the other extremity with the SMB connector at 90 should be connected to the SMB2 connector, printed on the soldering side of the master board. (see photo). MAPRME05 - Rev

152 5.15 External antenna with cable The cable should be made to pass above the master board close to the wall of the receiving case (beside the receiver decoder module). At the height of the SMB connectors of the base, the cable must run under it and turn externally around the fixing screws until it reaches the SMB2 connector. Replacement Disassembly Assembly 1. With the receiving unit disconnected from the power supply, fit together the different pieces of the antenna, fixing them to a metallic support plate. 4. Disassemble the antenna, separating the different parts from the support surface. 2. Insert one end of the cable into the antenna connector and one into the relative connector of the receiving case. 3. Disconnect the receiving unit. Extract the ends of the cable from the antenna connector and from the relative connector of the receiving case MAPRME05 - Rev.0

153 5.16 Cable for wiring with recovery diodes 5.16 Cable for wiring with recovery diodes Indications This cable is used for wiring recovery diodes in the command contacts of the electromagnetic devices (solenoid valves). Their function is to suppress the overvoltage generated by the opening of the contacts. It should therefore only be used with DC master boards. It is particularly useful for the contacts of the inductive load on/off commands. WARNING: only carry out wiring of this cable if the controlled machine does not already have devices for suppressing the overvoltages. Wiring When used, this cable with recovery diodes should only be wired to the relay contacts that command solenoid valves (as indicated in the electric diagram below). MAPRME05 - Rev